Foam compositions and uses thereof

ABSTRACT

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of, co-pending U.S.provisional applications entitled “FOAM COMPOSITIONS AND USES THEREOF”having Ser. Nos. 62/899,688 and 62/899,696, both filed on Sep. 12, 2019,the contents of which are incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to foams formed ofthermoplastic copolyesters, and in particular to foams formed ofthermoplastic copolyesters which are suitable for the footwear andrelated industries and uses thereof.

BACKGROUND

The design of athletic equipment and apparel as well as footwearinvolves a variety of factors from the aesthetic aspects, to the comfortand feel, to the performance and durability. While design and fashionmay be rapidly changing, the demand for increasing performance in themarket is unchanging. To balance these demands, designers employ avariety of materials and designs for the various components that make upathletic equipment and apparel as well as footwear.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the present disclosure will be readily appreciatedupon review of the detailed description, described below, when taken inconjunction with the accompanying drawings.

FIG. 1 is an elevation view of an article of footwear with a solecomponent according to an aspect of the invention.

FIG. 2 is an exploded view of the sole component of the article offootwear of FIG. 1.

FIG. 3 is a plan view of the bottom of the sole component of the articleof footwear of FIG.

FIG. 4 is a bottom view of an insert for use in a sole component of anarticle of footwear.

FIG. 5 is a top view of the insert of FIG. 4 inserted in a first portionto form a sole component.

FIG. 6 shows representative compression data for representative foamplaques comprising a disclosed composition and prepared using adisclosed method.

FIG. 7 shows a representative schematic illustrating a disclosed foamcomponent or article with a second thermoplastic composition.

FIG. 8 shows a representative schematic illustrating a disclosed methodfor determining peak and tail temperatures.

FIGS. 9A-9D show representative images of cross-sectional views of foamplaques prepared using a disclosed thermoplastic copolyester elastomerat different temperatures. Each image shows a scalar bar (500micrometers). Foamed plaques were prepared at the followingtemperatures: 175 degrees centigrade (FIG. 9A); 190 degrees centigrade(FIG. 9B); 205 degrees centigrade (FIG. 9C); and 245 degrees centigrade(FIG. 9D).

FIG. 10 shows a representative image of a cross-sectional view of a foamplaque prepared using a disclosed thermoplastic copolyester elastomer160 degrees centigrade. The image shows a scalar bar (500 micrometers).

FIG. 11 shows representative coefficient of friction on a wood surfacedata for various polymeric materials.

FIG. 12 shows representative coefficient of friction on a concretesurface data for various polymeric materials.

FIG. 13 shows representative coefficient of friction on a concretesurface data for various polymeric materials used in a blown outsole.

FIG. 14 shows representative specific gravity data for various polymericmaterials in unfoamed samples and various foamed samples.

DETAILED DESCRIPTION

The present disclosure is directed to a foam article which includes afirst component, i.e., a thermoplastic foam component compositionallycomprising a foamed first thermoplastic composition. In other words, thefoamed first thermoplastic composition retains its thermoplasticproperties, and can be recycled by melting the foamed firstthermoplastic composition, and re-forming the first thermoplasticcomposition it into a new foamed article or a new solid (i.e., unfoamed)article. The first component is a foam component that includes a foamedfirst thermoplastic composition having a multicellular foam structure.In some aspects, the multicellular foam structure is an open-cell foamstructure. In other aspects, the multicellular foam structure is aclosed-cell foam structure. In some aspects, the foamed firstthermoplastic composition comprises one or more copolyesters, such as,for example, one or more copolyester elastomers. In some aspects, thefirst thermoplastic composition further comprises one or morenon-polymeric ingredients, such as a filler or a nucleating agent or apigment. The one or more non-polymeric ingredients can comprise 5 weightpercent or less of the first thermoplastic composition based on thetotal weight of the first thermoplastic composition. It has been found,for thermoplastic foams, particularly thermoplastic foamscompositionally comprising at least one thermoplastic copolyesterelastomer, that including low levels (e.g., 5 weight percent or less) ofnon-polymeric ingredients such as fillers, nucleating agents andpigments can improve the consistency of the sizes of the cells in themulticellular thermoplastic foam. In addition to improving the cellstructure, including low levels of non-polymeric ingredients in thefirst thermoplastic composition can also increase recyclability of thefirst thermoplastic composition, due to the high polymeric content ofthese thermoplastic compositions. The first thermoplastic compositioncan be free of or essentially free of fillers. The first thermoplasticcomposition can be free of or essentially free of nucleating agents. Thefirst thermoplastic composition can be free or essentially free ofpigments. The first thermoplastic composition can be free of oressentially free of fillers and nucleating agents, or can be free oressentially free of fillers, nucleating agents, and pigments. The firstthermoplastic composition can be free of or essentially free ofnon-polymeric ingredients. The foam article is particularly useful as acushioning element.

In some aspects, the disclosed foam article also includes a secondcomponent comprising a second thermoplastic composition. In suchaspects, the second component can be disposed on or in at least aportion of the first component. The second component can comprise apolymeric layer disposed on at least a portion of an external surface ofthe foamed first thermoplastic composition of the first component. Thesecond component comprises a second thermoplastic composition whichretains its thermoplastic properties and can be recycled by melting thesecond thermoplastic composition, and re-forming the secondthermoplastic composition it into a new foamed article or a new solid(i.e., unfoamed) article. As both the first component and the secondcomponent are formed of thermoplastic compositions, the first and thesecond components need not be separated before being recycled. Forexample, the foam article can be recycled by grinding or shredding theentire article and forming a molten polymeric composition which is amixture of both the first thermoplastic composition and the secondthermoplastic composition. The second thermoplastic composition cancomprise a thermoplastic elastomer or a thermoplastic vulcanizatematerial. The second thermoplastic composition can comprise a one ormore thermoplastic styrene copolymer elastomers, includingstyrene-ethylene-butene-styrene (SEBS) copolymer elastomers. The secondthermoplastic composition can comprise one or more thermoplasticpolyurethane elastomers, alone or blended with other polymers such as,for example, an ethylene-vinyl alcohol copolymer, or a styrene copolymerelastomer. Second thermoplastic compositions which comprise athermoplastic copolyester elastomer, or a thermoplastic polyurethaneelastomer, or a thermoplastic styrene copolymer elastomer, or athermoplastic vulcanizate material, have been found to form strongthermal bonds with foamed first thermoplastic compositions comprisingone or more thermoplastic copolyester elastomers. The foam articledisclosed herein is particularly useful as a cushioning element. Thefoam article including the first component and the second component isparticularly useful as a cushioning element for an article of footwear,apparel or sporting equipment. For example, the first component of thefoam article can be a midsole or a midsole component. The secondcomponent of the foam article can be a ground contacting component suchas an outsole, or a protective element such as a rand, on an article offootwear, which provides a greater level of abrasion resistance orprovides better traction or which provides both, as compared to thefirst foam component alone. The second component of the foam article canbe a protective or reinforcing layer or a containment layer on the firstfoam component, such as when the first foam component is a cushioningelement, or in other applications. In some aspects, when the firstcomponent has an open-cell foam structure, the second component can be awater-resistant barrier to reduce or prevent water uptake by the opencell structure of the foam.

Conventionally, vulcanized and peroxide-cured natural and syntheticrubbers such as isoprene and polybutadiene rubbers have been used toform durable, abrasion-resistant outer protective layers for a widevariety of articles, including outsoles for articles of footwear. Rubberformulations used for outsoles also typically provide traction. Onedisadvantage of using conventional rubber materials is that thesematerials are highly crosslinked during the curing process, renderingthe cured rubber a thermoset material and making it difficult to recycleor reuse the cured rubber. Also, it can be difficult to bond othermaterials to the cured rubber. Both the rubber materials and foammaterials typically used in a wide variety of consumer good are highlycrosslinked materials, which are formed and cured separately and thenadhered to each other using an adhesive system. These adhesive systemsrequire several manually-intensive processing steps, such as cleaningthe surfaces, priming the surfaces, applying adhesive to the surfaces,and pressing the surfaces together to bond them.

It has been found that thermoplastic compositions (e.g., thermoplasticcompositions comprising one or more thermoplastic copolyester elastomer)can be used to form multicellular foams having advantageous propertiesfor use in consumer articles such as cushioning elements. When foamed asdescribed herein, these foams retain thermoplastic properties, making itpossible to readily recycle and reuse the thermoplastic compositions.Additionally, it has been found that these foams can be directly moldedand foamed onto other polymeric materials (i.e., onto secondthermoplastic compositions as described herein), which bonds the foamsecurely to the second thermoplastic composition with a thermal bondwithout the need for additional adhesives, or the manual process stepsof applying an adhesive system. The second thermoplastic compositionwhich is bonded to the thermoplastic foam can be a thermoplasticelastomeric material, such as a second thermoplastic composition asdescribed herein. Examples of both second thermoplastic compositionswhich, when used either in solid form or in a lightly foamed form (e.g.,having a specific gravity of 0.85 or greater) have been found which bothbond well to the thermoplastic copolyester-based foam during a moldingand foaming process, and which also provide high levels of abrasionresistance and traction under wet and dry conditions, are describedherein. When the second thermoplastic composition comprises a secondthermoplastic copolyester, the fact that the foam comprises a firstthermoplastic copolyester and that the polymeric layer comprises asecond thermoplastic copolyester composition provides the advantage thatthe entire article can easily be melted down and the combined materialcan be recycled. In this scenario, the second copolyester compositioncan each individually include one or more of the same individualcopolyesters present in the first thermoplastic copolyester composition,either in the same proportions or in different proportions.Alternatively, the first and second copolyester compositions can eachindividually comprise different copolyesters.

The foam components disclosed herein are formed by foaming thermoplasticcompositions comprising one or more thermoplastic elastomer into amulticellular foam having an open-cell or closed-cell foam structure. Insome examples, the one or more thermoplastic elastomer can comprise orconsist essentially of a thermoplastic copolyester elastomer. Examplesof thermoplastic copolyester elastomers include polymers which have oneor more carboxylic acid moieties present in the polymeric backbone, onone or more side chains, or both in the polymeric backbone and on one ormore side chains. The one or more carboxylic acid moieties of thethermoplastic copolyester can include a free carboxylic acid, a salt ofa carboxylic acid, or an anhydride of a carboxylic acid. In particularexamples, the carboxylic acid moiety can be an acrylic acid moiety or amethacrylic acid moiety. The foam articles comprising a multicellularopen-cell or closed-cell thermoplastic foam and a polymeric layer of thepresent disclosure are suitable for use in a variety of articlesincluding for athletic equipment and apparel, particularly footwear(e.g., athletic footwear midsoles/outsoles). As discussed below, themulticellular open-cell or closed-cell thermoplastic foam exhibits aunique balance of properties such as high energy efficiency or energyreturn, and low specific gravity. In some examples, the multicellularfoam also exhibits a high split tear and low compression set. Thepresence of the polymeric layer on at least a portion of the exteriorsurface of the foam can reduce or prevent liquid uptake by themulticellular foams, particularly multicellular open-cell foams,increasing their performance when used under conditions where the foamcome into contact with liquids. Furthermore, the thermoplastic foam canalso be reprocessed with minimal loss in physical properties (e.g., forrecycling), providing a solution for materials sustainability.

The second thermoplastic composition of the polymeric layer can beselected to allow the entire foam article to be recycled in a singlestep, without the need to remove or separate the polymeric layer fromthe foam. For example, the second thermoplastic composition can compriseone or more thermoplastic copolyesters.

The foam article or foam component comprising the thermoplastic c foamcan be formed by injection molding and foaming the thermoplasticcomposition as described herein, or by injection molding and foaming thethermoplastic composition as described herein into a foam preform andsubsequently compression molding the foam-preform into a finished foam.The second thermoplastic composition can be disposed onto an exteriorsurface of the foam component during an injection molding and foamingprocess, in which the first thermoplastic composition is injected into amold which includes the second thermoplastic composition, and the secondthermoplastic composition bonds to the foam during the molding process.Alternatively or additionally, the second thermoplastic composition canbe disposed onto the exterior surface of the foam component during acompression molding step, in which the foam component is compressionmolded in a mold which includes the second thermoplastic composition,and the second thermoplastic composition bonds to the foam during themolding process. Alternatively or additionally, the second thermoplasticcomposition can be disposed onto the foam component after the foamcomponent has been formed, such as, for example, by vacuum forming afilm comprising the second thermoplastic composition to the foamcomponent.

Articles Manufactured Using the Disclosed Foams.

Footwear 10 is an exemplary article of athletic footwear that includesthe thermoplastic foam of the present disclosure. While illustrated as arunning shoe, footwear 10 may alternatively be configured for anysuitable athletic performance, such as baseball shoes, basketball shoes,soccer/global football shoes, American football shoes, running shoes,cross-trainer shoes, cheerleading shoes, golf shoes, and the like. Whilean athletic shoe is exemplified in FIG. 1, it will be readily understoodthat some of the terminology employed will also apply to other articlesof footwear or to other styles of shoe. Footwear 10 includes an upper 12and a sole component 14 secured to upper 12. Sole component 14 can besecured to upper 12 by adhesive or any other suitable means. As usedherein, the sole component 14 can be a monolithic component formedentirely of the thermoplastic foam material as described herein, or amulti-component assembly formed of a plurality of monolithic components,where at least one of the monolithic components is formed entirely ofthe thermoplastic foam material as described herein.

Footwear 10 has a medial, or inner, side 16 and a lateral, or outer,side 18. For ease of discussion, footwear 10 can be divided into threeportions: a forefoot portion 20, a midfoot portion 22, and a heelportion 24. Portions 20, 22, and 24 are not intended to demarcateprecise areas of footwear 10. Rather, portions 20, 22, and 24 areintended to represent respective areas of footwear 10 that provide aframe of reference during the following discussion. Unless indicatedotherwise, directional terms used herein, such as rearwardly, forwardly,top, bottom, inwardly, downwardly, upwardly, etc., refer to directionsrelative to footwear 10 itself. Footwear 10 is shown in FIG. 1 in asubstantially horizontal orientation, as it would be positioned on ahorizontal surface when worn by a wearer. However, it is to beappreciated that footwear 10 need not be limited to such an orientation.Thus, in FIG. 1, rearwardly is toward heel portion 24 (to the right asseen in FIG. 1), forwardly is toward forefoot portion 20 (to the left asseen in FIG. 1), and downwardly is toward the bottom of the page as seenin FIG. 1. Top refers to elements toward the top of the view in FIG. 1,while bottom refers to elements toward the bottom of the view in FIG. 1.Inwardly is toward the center of footwear 10, and outwardly is towardthe outer peripheral edge of footwear 10.

The component can be a sole component, such as a sole component 14depicted in FIGS. 1-5, that includes a thermoplastic foam, including athermoplastic copolyester foam, as described herein. The component canbe an insert such as insert 36 or insert 60 depicted in FIGS. 4-5 thatincludes a thermoplastic foam described herein. The sole components andinserts for sole components can be made partially or entirely of athermoplastic foam described herein. Any portion of a sole component oran insert for a sole component can be made of a thermoplastic foamdescribed herein. For example, first portion 26 of the sole component(optionally including the ground engaging lower surface 44, such as theplurality of projections 46 and/or the groove 48 surrounding theprojections), the entire insert 36, portions 62 or 64 of insert 60, aseparate outsole component, or any combination thereof, can include athermoplastic foam as described herein. The sole components and insertscan be made by foaming thermoplastic compositions as described herein,for example by injection molding or by injection molding, optionallyfollowed by compression molding, as described herein. In some aspects,the thermoplastic foams can be formed by physical foaming of thethermoplastic compositions. The thermoplastic foams and components candemonstrate improved physical properties including one or more of anenhanced energy efficiency or energy return, an enhanced split tear, adecreased specific gravity, or a combination thereof.

Sole component 14, which is generally disposed between the foot of thewearer and the ground, provides attenuation of ground reaction forces(i.e., imparting cushioning), traction, and may control foot motions,such as pronation. As with conventional articles of footwear, solecomponent 14 can include an insole (not shown) located within upper 12.In some aspects, the sole component is an insole or sockliner or is amulti-component assembly including an insole or sockliner, can furtherinclude an insole or sockliner located within the upper, where theinsole or sockliner is formed entirely or partially of a thermoplasticfoam described herein. Articles of footwear described herein can includean insole or sockliner formed entirely or partially of a thermoplasticfoam described herein.

As can be seen in FIG. 2, sole component 14 consists of a first portion26 having an upper surface 27 with a recess 28 formed therein. Uppersurface 27 is secured to upper 12 with adhesive or other suitablefastening means. A plurality of substantially horizontal ribs 30 isformed on the exterior of first portion 26. In certain aspects, ribs 30extend from a central portion of forefoot portion 20 on medial side 16rearwardly along first portion 26, around heel portion 24 and forwardlyon lateral side 18 of first portion 26 to a central portion of forefootportion 20.

First portion 26 provides the external traction surface of solecomponent 14. In certain aspects it is to be appreciated that a separateoutsole component could be secured to the lower surface of first portion26. When a separate outsole component is secured to the lower surface offirst portion 26, the first portion 26 is a midsole component. In someaspects, the article is a midsole component for an article of footwear.In other aspects, the article is a combination midsole-outsole componentfor an article of footwear.

The article can be an insert. An insert 36 can be received in recess 28.As illustrated in FIG. 2, insert 36 can provide cushioning or resiliencyin the sole component. First portion 26 can provide structure andsupport for insert 36. In such aspects, first portion 26 can be formedof a material of higher specific gravity and/or hardness as compared toinsert 36 such as, for example, non-foam materials including rubber andthermoplastic polyurethane, as well as foam materials. In certainaspects, insert 36 can be formed of a thermoplastic foam as disclosedherein.

Insert 36 has a curved rear surface 38 to mate with curved rear surface32 of recess 28 and a transverse front surface 40 to mate withtransverse front surface 34 of recess 28. An upper surface 42 of insert36 is in contact with and secured to upper 12 with adhesive or othersuitable fastening means. For example, when there is an insert 36, arecess 28 can extend from heel portion 24 to forefoot portion 20. Incertain aspects, the rear surface 32 of recess 28 is curved tosubstantially follow the contour of the rear of heel portion 24 and thefront surface 34 of recess 28 extends transversely across first portion26.

As seen best in FIG. 3, a ground engaging lower surface 44 of firstportion 26 includes a plurality of projections 46. Each projection 46 issurrounded by a groove 48. A plurality of transverse slots 50 are formedin lower surface 44, extending between adjacent projections 46. Alongitudinal slot 52 extends along lower surface 44 from heel portion 26to forefoot portion 20.

FIGS. 4 and 5 show bottom and top views of an insert 60 which can beused in a sole component as described herein. Insert 60 is similar toinsert 36, but as illustrated in FIGS. 4 and 5, insert 60 is formed oftwo types of materials 62 and 64, where at least one of the materials isa thermoplastic foam as disclosed herein. FIG. 4 shows a bottom view ofinsert 60, while FIG. 5 shows a top view of insert 60 formed of twotypes of materials 62 and 64, with the insert placed inside a firstportion 66 to form a sole component 14. Inserts with more than two typesof materials, at least one of which is a thermoplastic foam as disclosedherein, can also be used. In the example illustrated in FIGS. 4 and 5, aportion of a first material 62 can be used in the heel region of theinsert, and a portion of a second material 64 can be used in the toeregion of the insert. A higher specific gravity material can be used tosupport the heel region, while a lower specific gravity material can beused to support the toe region. For example, the specific gravity of thefirst material can be at least 0.02 units greater than the specificgravity of the second material. The shape of the portions of the twomaterials 62 and 64 of the insert can be any suitable shape. Forexample, the heel region can be in the shape of a wedge. Inserts formedof two types of materials can be useful in running shoes, as well as inbasketball shoes.

In the articles comprising the foam articles or components including thethermoplastic foam, for example a thermoplastic copolyester foam havingan open cell structure, and the layer of a second thermoplasticcomposition disposed on at least a portion of an exterior surface of thefoam as described herein. Referring to FIG. 7, in an aspect, a foamcomponent 70 can have a foam portion 72, comprising a polymeric materialthat comprises a thermoplastic copolyester multicellular foam having anopen-cell or closed-cell foam structure. The foam portion 72 has one ormore sides that, when the foam component 70 is disposed in an articlesuch as an article of footwear, are oriented toward an exterior facingside or surface of the article (e.g. an outer peripheral edge of articleof footwear 10 of FIG. 1). A polymeric layer 74 is disposed on at leasta portion of an exterior facing side or surface of the foam portion 72.The polymeric layer 74 comprises a second thermoplastic composition thatmay be the same as or different from the first thermoplastic compositionof the foam portion 72. According to aspects, the polymeric layer 74 isnot a foamed material. The polymeric layer 74 can function as anoutsole, for example, which can provide improved abrasion resistance onone or more surfaces of the foam portion 72.

In some aspects, the article can be something other than a solecomponent. For example, the article can be an upper or an uppercomponent. An upper component refers to a piece that is stitched orotherwise joined with one or more other pieces to form an upper portionfor an article of footwear. The materials in the upper generallycontribute to characteristics such as breathability, conformability,weight, and suppleness or softness. A lower component refers to a piecethat is joined with one or more other pieces to form the lower portionof an article of footwear. The lower can include, for example, theoutsole and midsole. The choice of outsole materials and design willcontribute, for instance, to the durability, traction, as well as to thepressure distribution during use. The midsole materials and designcontribute to factors such as the cushioning and support. Grinderycomponents include all of the additional components that can be attachedto the upper, lower, or both. Grindery components can include, forexample, eyelets, toe puffs, shanks, nails, laces, velcro, catches,backers, linings, padding, heel backings, heel foxings, toe caps, etc.

The upper can be a lasted upper. A “lasted upper,” as used herein,refers to an upper that is formed into the shoe shape prior toattachment to the sole by one or more mechanical means. The lasted uppercan include a heel counter formed to shape the heel of the upper. Thelasted upper can include a strobel or a strobel board attached to theupper, typically via a strobel stitch.

While the thermoplastic foams described herein, including thethermoplastic copolyester foams described herein, can be used for makingany of a variety of components, including a variety of components for anarticle of footwear, in particular aspects the components include amidsole, an outsole, an insole, or an insert. Additional articles caninclude a tongue padding, a collar padding, and a combination thereof.As described above and detailed more completely below, the articlescomprising the thermoplastic foams described herein can exhibit a uniquebalance of beneficial physical properties such as high energy efficiencyor energy return, and low specific gravity. Furthermore, thethermoplastic foam can also be reprocessed with minimal loss in physicalproperties (e.g., for recycling), providing a solution for materialssustainability.

In some instances a disclosed article can comprise a first componentcomprising a foamed thermoplastic composition, such as a foamedthermoplastic copolyester composition, and a second component comprisinga second thermoplastic composition. An article comprising the firstcomponent with the second thermoplastic composition can be characterizedby good bonding strength between the second thermoplastic compositionand the foam component. The ply adhesion strength between the secondthermoplastic composition and the foam component is greater than 2.5 kgforce/centimeter or greater than 3.0 kg force/centimeter, whendetermined using the Ply Adhesion Test method described herein.

First Components

The first component is a foam component comprising a thermoplasticcomposition comprising one or more thermoplastic elastomers. In oneaspect, the thermoplastic composition is a thermoplastic copolyestercomposition comprising one or more thermoplastic copolyester elastomers.The first component can be a component such as, but not limited to, acomponent of a midsole or a midsole component. It is understood that thefirst component comprises a foamed thermoplastic composition. Forexample, a thermoplastic composition includes at least 90 weightpercent, or at least 95 weight percent, or at least 99 weight percent ofthermoplastic polymers, such as, for example, the thermoplasticcopolyester disclosed herein, based on the total weight of thethermoplastic composition. In some instances, the polymeric component ofthe thermoplastic composition, which includes all the polymers presentin the thermoplastic composition, includes or consists essentially ofone or more thermoplastic elastomers, such as one or more of thedisclosed thermoplastic copolyester elastomers. In other words, the onlypolymers present in the thermoplastic composition can be thermoplasticelastomers, or the only polymers present in the thermoplasticcomposition can be thermoplastic copolyester elastomers.

Second Components

The second component comprising a second thermoplastic composition canbe a component such as, but not limited to, a component of an outsole oran outsole component. It is understood that the second component can befoamed, partially foamed, or essentially unfoamed. In some instances thesecond component is a foamed component, i.e., a second foam component.In other instances, the second component is an unfoamed component, i.e.,a solid component. In some instances, the second thermoplasticcomposition is a disclosed thermoplastic composition, such as athermoplastic copolyester composition. For example, a secondthermoplastic composition can include at least 90 weight percent, or atleast 95 weight percent, or at least 99 weight percent of thermoplasticelastomers as disclosed herein, based on the total weight of the secondthermoplastic composition. In some instances, the second thermoplasticcomposition includes a polymeric component consisting essentially of oneor more disclosed thermoplastic elastomers, including one or moredisclosed copolyester elastomers. In other instances, the secondthermoplastic composition can include a polymeric component which isessentially free of a thermoplastic copolyester, e.g., the polymericcomponent can consist essentially of a thermoplastic polyurethaneelastomer or a thermoplastic vulcanizate material as disclosed herein.In still other instances, a second thermoplastic composition can includea mixture of a disclosed thermoplastic copolyester and a polymericmaterial that is not a disclosed thermoplastic copolyester, e.g., athermoplastic elastomer or thermoplastic vulcanizate material.

Characteristics of Thermoplastic Copolyester Foam Components.

As discussed herein above, a first component can be foam component,i.e., a first foam component, comprising a disclosed first thermoplasticcomposition. In some instances, a second component can be foamcomponent, i.e., a second foam component, comprising a disclosed secondthermoplastic composition. That is, each of the first or second foamcomponents can independently comprise a disclosed thermoplastic foamcomponent. It is understood herein throughout that reference to a“thermoplastic foam” is inclusive of a first foam component, a secondcomponent, or both a first and a second foam components, and that eachof the first and second foam components can independently comprise oneor more disclosed thermoplastic compositions as disclosed herein below.A disclosed thermoplastic foam can exhibit various beneficialproperties.

For example, the thermoplastic foam can exhibit a beneficial split tear,for example a high split tear for a sole component in an article offootwear. In some aspects, the thermoplastic foam can have a split tearvalue of greater than about 1.5 kilogram/centimeter (kg/cm), or greaterthan about 2.0 kg/cm, or greater than about 25 kg/cm, when determinedusing the Split Tear Test Method described herein. In some aspects, thethermoplastic foam can have about 1.0 kg/cm to 4.5 kg/cm, about 1.5kg/cm to 4.0 kg/cm, about 2.0 kg/cm to 4.0 kg/cm, about 2.0 kg/cm to 3.5kg/cm, or about 2.5 kg/cm to 3.5 kg/cm, when determined using the SplitTear Test method described herein. In some aspects, the thermoplasticfoam is injection molded, or is injection molded and subsequentlycompression molded in a separate compression mold having differentdimensions than the mold used in the injection molding step. Thethermoplastic foam can have a split tear of about 0.08 kg/cm to 4.0kg/cm, about 0.9 kg/cm to 3.0 kg/cm, about 1.0 to 2.0 kg/cm, about 1.0kg/cm to 1.5 kg/cm, or about 2 kg/cm. In some aspects, the thermoplasticfoam the thermoplastic foam is injection molded, and has have a splittear of about 0.07 kg/cm to 2.0 kg/cm, or about 0.8 kg/cm to 1.5 kg/cm,or about 0.9 to 1.2 kg/cm, about 1.5 kg/cm to 2.2 kg/cm.

The specific gravity of a disclosed thermoplastic foam is also animportant physical property to consider when using a foam for in anarticle of footwear or athletic equipment. As discussed above, thethermoplastic foam of the present disclosure exhibits a low specificgravity, which beneficially reduces the weight of midsoles or othercomponents containing the thermoplastic foam. The thermoplastic foams ofthe present disclosure can have a specific gravity of from 0.02 to 0.22,or of from 0.03 to 0.12, or of from 0.04 to 0.10, or from 0.11 to 0.12,or from 0.10 to 0.12, from 0.15 to 0.2; 0.15 to 0.30, when determinedusing the Specific Gravity Test Method described herein. Alternativelyor in addition, the thermoplastic foam can have a specific gravity offrom 0.01 to 0.10, or of from 0.02 to 0.08, or of from 0.03 to 0.06;0.08 to 0.15; or from 0.10 to 0.12, when determined using the SpecificGravity Test Method described herein. For example, the specific gravityof the thermoplastic foam can be from or from 0.15 to 0.20, or can befrom 0.10 to 0.12. The thermoplastic foam can be injection molded, orcan be injection molded and subsequently compression molded. In someaspects, the thermoplastic foam has a specific gravity of about 0.7 orless, or 0.5 or less, or 0.4 or less, or 0.3 or less, when determinedusing the Specific Gravity Test Method described herein. In someaspects, the thermoplastic foam, including thermoplastic foam present inmidsoles and midsole components, can have a specific gravity of about0.05 to 0.25, about 0.05 to 0.2, about 0.05 to 0.15, about 0.08 to 0.15,about 0.08 to 0.20, about 0.08 to 0.25, or about 0.1 to 0.15, whendetermined using the Specific Gravity Test Method described herein. Insome aspects the thermoplastic foam has a specific gravity of about 0.15to 0.3, about 0.2 to 0.35, or about 0.15 to 0.25, when determined usingthe Specific Gravity Test Method described herein.

In a particular example, the first component is a cushioning element foran article of footwear, and the thermoplastic foam of the firstcomponent has a specific gravity from 0.05 to 0.25, or from 0.17 to0.22, or from 0.18 to 0.20, when determined using the Specific GravityTest Method described herein. The thermoplastic foam can be a physicallyfoamed thermoplastic foam, such as physically foamed thermoplastic foamformed using a single-phase solution of a supercritical fluid and athermoplastic composition described herein. The thermoplasticcomposition can be a thermoplastic copolyester composition comprisingone or more thermoplastic copolyester elastomer.

The thermoplastic foam portion of the article or component of an articlecan have a stiffness of about 200 kPa to about 1000 kPa, or about 300 toabout 900 kPa or about 400 to about 800 kPa or about 500 to about 700kPa, when determined using the Cyclic Compression Test with the45-millimeter diameter cylindrical sample. The thermoplastic foamportion of the article or component of an article can have a stiffnessof about 200 kPa to about 1000 kPa, or about 300 to about 900 kPa orabout 400 to about 800 kPa or about 500 to about 700 kPa, whendetermined using the Cyclic Compression Test with the footform sample.The thermoplastic foam article or article component can be formed byinjection molding, or by injection molding and subsequently compressionmolding.

The thermoplastic foam portion of the article or component of an articlecan have an Asker C durometer hardness of from about 30 to about 50, orfrom about 35 to about 45, or from about 30 to about 45, or from about30 to about 40, when determined using the Durometer Hardness Testdescribed herein

The energy input of a foam is the integral of the force displacementcurve during loading of the foam during the Cyclic Compression test. Theenergy return of a foam is the integral of the force displacement curveduring unloading of the foam during the Cyclic Compression test. Thethermoplastic foam portion of the article or component of an article canhave an energy return of about 200 millijoules (mJ) to about 1200 mJ, orfrom about 400 mJ to about 1000 mJ, or from about 600 mJ to about 800mJ, when determined using the Cyclic Compression Test with a45-millimeter diameter cylindrical sample.

The energy efficiency, a measure of the percentage of energy thethermoplastic foam portion of the article or component returns when itis released after being compressed under load, can provide improvedperformance for athletic shoes, e.g. for reducing energy loss ordissipation when running. This is especially true for running and otherathletic shoes. In some aspects, the thermoplastic foam portion of thearticles and components provided herein have an energy efficiency ofabout 50 percent to 97 percent, about 60 percent to 95 percent, about 60percent to 90 percent, about 60 percent to 85 percent, about 65 percentto 85 percent, or about 70 percent to 85 percent, when determined usingthe Cyclic Compression Test with a 45-millimeter diameter cylindricalsample.

By modifying the conditions and components used to make the foams one ormore properties of the foam can be modified. In one aspect, when thefoam is the physically foamed product of a single-phase solution of asupercritical fluid and the first thermoplastic composition in a moltenstate, the resulting foam can have a reduced specific gravity as well ashigh energy efficiency or energy return. In one aspect, additives suchas nucleating agents and fillers are not used or are used at low levels,as it has been found that the use of non-polymeric ingredients candecrease the consistency of the size of the cells in the multicellularfoam, particularly when foaming thermoplastic copolyester compositions.Additionally, the inclusion of higher levels of non-polymeric additivessuch as fillers, nucleating agents and pigments, can make recycling thefoams more challenging.

In other aspects, the temperature at which the molten firstthermoplastic composition is foamed can modify the properties of thefoam. In one aspect, the foaming temperature of the thermoplasticcomposition, i.e., the temperature of the thermoplastic composition atthe point that foaming is initiated, is from about the meltingtemperature of the thermoplastic composition to about 50 degreescentigrade, or about 40 degrees centigrade, or about 30 degreescentigrade, or about 20 degrees centigrade above the tail temperature ofthe thermoplastic composition. Alternatively, the foaming temperaturecan be from the crystallization temperature of the thermoplasticcomposition to about 50 degrees centigrade, or about 40 degreescentigrade, or about 30 degrees centigrade, or about 20 degreescentigrade above the crystallization temperature of the thermoplasticcomposition. The melting temperature, the tail temperature, and thecrystallization temperature of the thermoplastic composition can bedetermined using differential scanning calorimetry (DSC). In thisaspect, properties such as reduced specific gravity, consistent foamcell size, and/or high energy efficiency or energy return can beachieved, particularly when foaming thermoplastic copolyestercompositions.

The resulting foams can have a multicellular closed cell or open cellfoam structure. Cells are the hollow structures formed during thefoaming process, in which bubbles are formed in the polymeric materialby the blowing agents. The cell walls are generally defined by thepolymeric material. The cells can be entirely enclosed by the polymericmaterial, or they can be at least partially open, e.g., interconnectedwith one or more adjacent cells. “Closed cell” structures refer tostructures in which at least 60 percent or more of the cells are closedcells, or at least 80 percent of the cells are closed cells, or at least90 percent of the cells are closed cells, or at least 95 percent of thecells are closed cells. As described herein “open cell” structuresrefers to foam structures in which less than about 15 percent or lessthan about 10 percent or 5 percent or less than 4 percent, or less than3 percent or less than 1 percent of the cells are closed cells.

The disclosed thermoplastic foams may have an average cell diameter offrom about 50 micrometers to about 1000 micrometers, or from about 80micrometers to about 800 micrometers, or from about 100 micrometers toabout 500 micrometers. The disclosed thermoplastic foams can have anaverage cell diameter of from about 50 micrometers to about 500micrometers, or from about 70 micrometers to about 300 micrometers, orfrom about 80 micrometers to about 200 micrometers, or from about 50micrometers to about 200 micrometers.

The proportion of cells in the foam having an average cell diameter ofabout 50 micrometers to about 300 micrometers is preferably not lessthan 40 percent relative to all the cells, or not less than 50 percentor not less than 60 percent relative to all the cells. If the proportionof cells is less than 40 percent, the cell structure will tend to benonuniform and/or have a coarse cell structure. As used herein, a“coarse cell structure” refers to a foam structure in which the averagecell diameter is greater than 1 millimeter, and/or for greater than 20percent of the cells, a 1 millimeter line drawn across the largestdimension of the cell, will not cross a cell wall or a strut (i.e., anopen cell wall or portion thereof).

The number of open cells and/or closed cells and cell diameter of thecells of the foam can be determined visually, for example by capturingan image of a cut surface with a camera or digital microscope,determining the number of cells, number of open cells and/or number ofclosed cells, and determining the average cell diameters of across-section of a sample of the foam. For cells of a closed cell foam,the diameters are determined from cell wall to cell wall. For cells ofan open cell foam, the diameters are determined between planes formed bythe intersections of supporting struts between cells (i.e., an open cellwall or portion thereof). In one aspect, a portion of the foam can becut and the cells in the cross-sectional area can be examined visuallyunder a microscope or by software to determine the percentage of thecells within a region which are open or closed and to determine theaverage size of the cells. In one aspect, a sample from a region of thefoam article which represents from about 75 percent to about 100 percentof the maximum thickness of the foam article can be used to determinethe nature and size of the cells.

Methods of Manufacturing Disclosed Foams.

In some examples, the disclosed foams can be prepared by various methodsas disclosed herein and as known in the art. That is, disclosed articlesor components of articles such as midsoles, midsole components, insertsand insert components can be prepared by injection molding a meltcomposition comprising a first thermoplastic composition as describedherein using a physical blowing agent and/or chemical blowing agent. Adisclosed foam component, e.g., a disclosed first foam component or adisclosed foam second foam component, can be prepared by the methodsdisclosed herein below.

Disclosed herein are methods for making a foam article or component, themethod comprising: forming a mixture of molten first thermoplasticcomposition and a blowing agent, wherein the first thermoplasticcomposition comprises a disclosed thermoplastic elastomer; injecting themixture into a mold cavity; foaming the molten first thermoplasticcomposition, thereby forming a foamed molten first thermoplasticcomposition; solidifying the foamed molten first thermoplasticcomposition, thereby forming a foam article having a multicellular foamstructure; and removing the foam article from the mold cavity. In oneaspect, the first thermoplastic composition is a first thermoplasticcopolyester composition comprising a disclosed thermoplastic copolyesterelastomer, and the multicellular foam structure is an open cellmulticellular foam structure.

Also disclosed are methods for making a foam article or component, themethod comprising: forming a mixture of molten first thermoplasticcomposition and a blowing agent, wherein the first thermoplasticcomposition comprises a disclosed thermoplastic elastomer; injecting themixture into a mold cavity; foaming the molten first thermoplasticcomposition, thereby forming a foamed molten first thermoplasticcomposition; solidifying the foamed molten first thermoplasticcomposition, thereby forming a foam article having a multicellular foamstructure; and removing the foam article from the mold cavity; wherein,during the injecting, the mixture has an injection temperature; andwherein the injection temperature is from about the melting temperatureof the thermoplastic elastomer to about 50 degrees centigrade above thetail temperature of the thermoplastic composition. In one aspect, thefirst thermoplastic composition is a first thermoplastic copolyestercomposition comprising a disclosed thermoplastic copolyester elastomer,and the multicellular foam structure is an open cell multicellular foamstructure.

Also disclosed are methods for making a foam article or component, themethod comprising: forming a mixture of molten first thermoplasticcomposition and a blowing agent, wherein the first thermoplasticcomposition comprises a disclosed thermoplastic elastomer; injecting themixture into a mold cavity; foaming the molten first thermoplasticcomposition, thereby forming a foamed molten first thermoplasticcomposition; solidifying the foamed molten first thermoplasticcomposition, thereby forming a foam article having a multicellular foamstructure; and removing the foam article from the mold cavity; whereinthe foaming occurs at a foaming temperature; and wherein the foamingtemperature is from about the melting temperature of the thermoplasticelastomer to about 50 degrees centigrade above the tail temperature ofthe thermoplastic elastomer. In one aspect, the first thermoplasticcomposition is a first thermoplastic copolyester composition comprisinga disclosed thermoplastic copolyester elastomer, and the multicellularfoam structure is an open cell multicellular foam structure.

Dynamic scanning calorimetry (DSC) is used to determine the meltingtemperature, the tail temperature, and the crystallization temperatureof a thermoplastic elastomer, and an exemplary method is describedherein below. Briefly, 10-30 mg pieces of undried resin pellets arecycled from −90 degrees centigrade to 225 degrees centigrade at 20degrees centigrade/min and cooled to −90° C. at 10° C./min. In someinstances, experiments are run using a heat-cool-heat profile with aramp rate of 10 degrees centigrade per min, minimum temperature of 0degrees centigrade and maximum temperature of 250 degrees centigrade.Analyses should be determined in duplicate and averaged. The meltingtemperature and crystallization temperature values are recorded. Themelt “peak” is and the crystallization “peak” are identified as thelocal maximum of the melting or crystallization. If there is more thanone peak in the DSC curve, the peak occurring at hotter temperatures ischosen as the temperature reference. The tail is identified as theintersection of the tangent of the line of the higher temperature sideof the peak with the extrapolated baseline. A schematic illustrating themethod for determining melting peak and tail temperatures is shown inFIG. 8.

For example, the disclosed foamed first thermoplastic compositions canbe prepared using a suitable extruder. An extruder (e.g., single or twinscrew) can be used to provide a composition. The extruder can have amotor to turn a screw inside the extruder. Extruder may be a singlescrew or twin screws made of individual elements of various sizes andpitches appropriate for mixing or kneading the specific materials used.In some examples, the extruder has a twin screw.

The various components that make up the first thermoplastic compositionused to form the thermoplastic foam of the various examples describedherein are added into the extruder through one or more port. The variouscomponents can be added as a melt or as appropriately-sized solidparticles, for example chips or pellets, that are melted in section asthey are mixed in the barrel of the extruder. The contents of theextruder can be heated to melt the composition. A supercritical fluidcan be added into the melt as a physical blowing agent. In particularexamples, the thermoplastic foam is prepared by using a physical blowingagent which foams the thermoplastic composition after the pressure isdropped to a level at which the supercritical fluid phase transitionsinto a gas, such as after it exits the extruder, and the thermoplasticfoam is thus substantially free of a chemical blowing agent ordecomposition product thereof.

The compositions can be added as a melt at a temperature close to themelting temperature of the first thermoplastic composition.

If a chemical blowing agent is used, the processing temperature withinthe extruder used can be sufficiently below the temperature that wouldtrigger the blowing agent. In order to foam the first thermoplasticcomposition, the temperature near the exit of the extruder or within thebarrel of the injector can be increased in order to heat thethermoplastic composition to a temperature close to or at the triggeringtemperature of a chemical blowing agent, thereby producing a chemicallyfoamed thermoplastic foam as the composition exits the extruder (e.g.,as the composition is injected into an injection mold).

Alternatively or in addition, a physical blowing agent can be used tofoam the composition to form a physically foamed thermoplastic foam, ora physically and chemically foamed thermoplastic foam. For example, asupercritical fluid such as supercritical carbon dioxide orsupercritical nitrogen can be mixed with the molten first thermoplasticcomposition in the barrel of the extruder to form a single-phasesolution. As used herein, “single-phase” refers to a composition wheretwo or more components are present where there is no discernible phaseseparation amongst the components. For example, when a supercriticalfluid is mixed with molten first thermoplastic composition, theresulting composition is a homogeneous solution where droplets ofsupercritical fluid are not detected. As the single-phase solution exitsthe extruder or the injector, the pressure drop between the higherpressure in the extruder or injector and the lower pressure outside theextruder or injector causes the supercritical fluid to transition to thegas phase and foam the first thermoplastic composition.

Various examples include methods of manufacturing an article of footwearor components for an article of footwear. In some examples, the methodsof manufacturing an article of footwear include injection molding afirst thermoplastic composition to form a thermoplastic foam describedherein to produce a foam article or component of an article, such as anarticle of footwear. The article or component of an article can be amidsole or a component of a midsole, and the method can includeproviding an upper and an outsole for an article of footwear; andcombining the midsole or midsole component, the upper, and the outsoleto make an article of footwear. In some examples, the method ofmanufacturing the article of footwear includes combining an articlecomprising a thermoplastic foam and an upper to make an article offootwear.

The articles or components of articles such as midsoles, midsolecomponents, inserts and insert components can be prepared by injectionmolding a molten first thermoplastic composition described herein usinga physical blowing agent. The injection molding can use a screw-typeinjector that allows for maintaining and controlling the pressure in theinjector barrel. The injection molding machine can allow metering anddelivering a supercritical fluid such as supercritical carbon dioxide ornitrogen into the composition prior to injection. The supercriticalfluid can be mixed into the first thermoplastic composition within theinjection barrel to form a single-phase solution, and then thesingle-phase solution can be injected into the mold cavity. A drop inpressure within the mold cavity can cause the supercritical fluid toexpand to create cell nuclei and expand the cells to form the foamwithin the mold cavity. The injection molding system used to form thethermoplastic foam can include a physical foaming process, such as, forexample the “MUCELL” process (Trexel, Wilmington, Del., USA).

The thermoplastic r foams described herein can be made using a processthat involves impregnating a first thermoplastic composition (e.g., ator above a softening temperature of the composition) with a physicalblowing agent at a first concentration or first pressure. As usedherein, the term “impregnating” generally means dissolving or suspendinga physical blowing agent in a first thermoplastic composition. Theimpregnated first thermoplastic composition can then be foamed, or canbe cooled (when applicable) and re-softened (when applicable) forfoaming at a later time. In particular examples, the impregnated firstthermoplastic composition is a single-phase solution comprisingsupercritical carbon dioxide or nitrogen and the molten thermoplasticcomposition.

The impregnated first thermoplastic composition is foamed by reducingthe solubility of the physical blowing agent in the single-phasesolution through pressure or temperature changes. The reduction insolubility of the physical blowing agent can release additional amounts(e.g., to create a secondary expansion of an originally-formed foam) ofthe impregnated physical blowing agent from the first thermoplasticcomposition, to further foam the first thermoplastic composition,forming a thermoplastic foam having a multicellular foam structure.

In addition to injection molding, the thermoplastic foam of the presentdisclosure can be foamed and molded using various processes known in theart. For example, the thermoplastic foam can be formed into slab foam,filament or strand foams, particulate (e.g., bead) foams of variousshapes and sizes, etc. These various forms of foam can then be used indifferent ways. For example, like injection molded foam, slab foam andfilament or strand foam can be used directly as a finished foam article,or can be shaped (e.g., cut, buffed, or trimmed) to form a finished foamarticle, or can be compression molded to form a finished foam article.Optionally, the thermoplastic foam can be subjected to annealingprocesses as part of forming the finished foam article. Pellets of thecompositions can be used to form individual particulate thermoplasticfoams, or can be foamed and molded to form unitary molded foam articlescomposed of individual portions of foam affixed to each other.

The thermoplastic foams of the various examples described herein may befurther shaped or molded by any of the methods known for formingarticles from thermoplastic materials. Optionally, the thermoplasticfoams of the present disclosure which have been foamed using anysuitable foaming process (e.g., foaming using a physical and/or chemicalblowing agent), including by injection molding using only a physicalblowing agent, can then be compression molded to form a compressionmolded foam.

The thermoplastic foam of the present disclosure can be prepared by aprocess comprising (i) softening a first thermoplastic composition(e.g., by heating at a first temperature at or above a softeningtemperature of the composition); (ii) simultaneously or sequentiallywith the softening (when applicable), contacting the first thermoplasticcomposition with a first concentration or first pressure of a physicalblowing agent sufficient to drive an amount of the physical blowingagent into the first thermoplastic composition or combine the physicalblowing agent with the first thermoplastic composition; (iii) changingthe concentration or pressure (e.g., decreasing the pressure orconcentration) of the physical blowing agent to a second concentrationor second pressure that is effective to foam the first thermoplasticcomposition, thereby forming a thermoplastic foam (e.g., a thermoplasticfoam having a multicellular structure); and, (iv) following thechanging, cooling (when applicable) the thermoplastic foam to (e.g.,cooling to a temperature below the softening temperature of thecomposition), to form a solidified thermoplastic foam.

The thermoplastic foam of the present disclosure can be prepared by (i)contacting (e.g., dissolving or suspending) the first thermoplasticcomposition with a first concentration of a chemical blowing agent, insome examples, at or above a softening temperature of the firstthermoplastic composition (ii) triggering the chemical blowing agent tofoam the first thermoplastic composition, thereby forming athermoplastic foam (e.g., a thermoplastic foam having a multicellularstructure); and, (iii) following the triggering, in some examples,cooling the thermoplastic foam to, e.g., a temperature below itssoftening temperature, to form a solidified thermoplastic foam. In someexamples, the “triggering” of the chemical blowing agent is performed byany suitable method, including heating the composition comprising aconcentration of the chemical blowing agent to a temperature sufficientto “trigger” the chemical blowing agent, wherein the concentration ofthe chemical blowing agent is effective to foam the first thermoplasticcomposition, thereby forming a thermoplastic foam (e.g., a thermoplasticfoam having a multicellular structure). In some examples, the contactingcomprises contacting at a pressure of from about 10 MPa to about 100 MPa(e.g., from about 30 MPa to about 100 MPa, about 20 MPa to about 80 MPa,about 30 MPa to about 60 MPa or about 40 MPa to about 70 MPa).

Chemical blowing agents may be endothermic or exothermic, which refersto a type of decomposition they undergo to produce the gas for foaming.The decomposition may be a result of inputting thermal energy into thesystem. Endothermic blowing agents absorb energy and typically release agas, such as carbon dioxide, upon decomposition. Exothermic blowingagents release energy and generate a gas, such as nitrogen, whendecomposed. Regardless of the chemical blowing agent used, thermalvariables of the first thermoplastic composition being molded andthermal variables of the blowing agent to be decomposed are coupledtogether such that process parameters are selected so that the firstthermoplastic composition can be molded and the blowing agent candecompose at an appropriate phase of the molding operation.

The disclosed foamed first thermoplastic compositions and articles canbe prepared by using all or some of the elements of conventionalinjection molding systems such as those disclosed in U.S. Patent Appl.No. 62/734,912, which is incorporated herein by reference. Briefly, thesystem provides for decreased pressure losses across the system as wellas to control (e.g., deliberately increase or decrease) the elongation,apparent shear, and/or zero shear viscosities of the molten firstthermoplastic composition that is flowed into the mold. The method caninclude flowing a molten first thermoplastic composition into a shottuning chamber from an upstream device and adjusting a temperature, apressure, or both, within the shot tuning chamber to create a tunedmolten first thermoplastic composition. The method additionally includesflowing the tuned molten first thermoplastic composition into a moldcavity from the shot tuning chamber. It will be appreciated thatfine-tuning the temperature of and/or pressure applied to the moltenfirst thermoplastic composition enables the system to have a desiredimpact on the physical and mechanical properties of the molded article.In particular, the temperature of the molten first thermoplasticcomposition may be controlled to achieve a desired range ofshear/extensional viscosities, which reduces (e.g., substantiallyeliminates) uncontrolled bubble growth and/or nucleation. In oneexample, the method may also include adjusting (e.g., increasing and/ordecreasing) a pressure in the mold cavity via a gas counter pressure(GCP) assembly prior to or while the molten first thermoplasticcomposition is flowed from the shot tuning chamber or directly from theinjector into the mold cavity. In such an example, the molten firstthermoplastic composition may be flowed into the mold cavity atpressures well above ambient pressure. Furthermore, GCP may beintroduced into the mold cavity to control nucleation and bubble growthduring polymer foaming as well as increase surface quality of the moldedarticle. Nucleation and bubble growth control can enhance cell densityuniformity, consistency of cell diameters, and mechanical properties ofthe thermoplastic foam. In some examples, the improvement in celldensity homogeneity or consistency of cell diameters may be particularlybeneficial in thermoplastic foams having low specific gravities suchless than or equal to 0.3 and/or in foam components having largedimensions such as articles having a thickness that is ≥1.0 cm, forinstance.

The system can include a shot tuning chamber configured to receive amolten first thermoplastic composition from an upstream device. The shottuning chamber is also configured to adjust one or more of a temperatureof and a pressure applied to the molten first thermoplastic compositionto create an adjusted molten first thermoplastic composition and todispense the adjusted molten first thermoplastic composition. In thisway, the system can selectively adjust tuning chamber temperature and/orpressure to achieve desired properties, as previously mentioned. In oneexample, the system may further include an adjustable mold runnerconfigured to regulate fluidic communication between the shot tuningchamber and a mold cavity in a mold.

In another example, the system can comprise a GCP assembly coupled tothe mold cavity and configured to regulate an amount of counter pressuregas flow into and out of the mold cavity. Providing GCP adjustmentallows for tuning of the first thermoplastic composition as it entersand cools in the mold.

Alternatively, the disclosed foams and articles can be prepared usingmethods and systems as described in International Patent Appl. No.PCT/US2018/035128. Briefly, the method can comprise a method for moldinga single-phase solution comprised of a thermoplastic composition and asupercritical fluid. The single-phase solution is maintained underpressure during the molding operation to prevent a cellular structurefrom being formed by the supercritical fluid in the single-phasecomposition coming out of solution. The mold cavity in which thesingle-phase solution is introduced for molding purposes is pressurizedto a mold pressure that is sufficient to maintain the single-phasesolution as a single-phase solution as the mold cavity is filled.Subsequent to filling the mold cavity with the single-phase solutionunder pressure, the single-phase solution may solidify, entrapping thesupercritical fluid. Alternatively, before being solidified, thesingle-phase solution may be exposed to a reduction in pressure causingthe entrapped supercritical fluid to phase transition to a gas andexpand the softened thermoplastic composition to form a multicellularstructure before the thermoplastic composition is solidified into asolidified multicellular foam.

The method can include forming the single-phase solution, such asthrough introduction of a supercritical fluid with a first thermoplasticcomposition that is melted, e.g., at a temperature of from about themelting temperature of the thermoplastic elastomer of the thermoplasticcomposition up to about 50 degrees centigrade above the melting tailtemperature of the thermoplastic elastomer as described herein, in aninjection molding apparatus's barrel (e.g., screw) that is effective tomix the supercritical fluid and the molten thermoplastic composition,forming a single-phase solution while under pressure. The methodcontinues with pressurizing a mold cavity of a mold above atmosphericpressure to a mold pressure. Atmospheric pressure is a pressure of theenvironment in which the mold cavity is exposed (e.g., generalenvironment pressure). The mold pressure is at least a pressure tomaintain the single-phase solution as a single single-phase. The methodfurther includes injecting the single-phase solution into thepressurized mold cavity. The method also includes maintaining at leastthe mold pressure in the mold cavity during the injecting of thesingle-phase solution. As a result, the pressure in the mold cavityprevents the supercritical fluid from phase-transitioning to a gas andfrom coming out of solution to form a two-phase mixture (e.g., foaming)upon exit from the injection molding apparatus. As the pressure ismaintained, premature foaming as the thermoplastic composition isinjected from the injection molding apparatus is avoided to allow adecoupling of process parameters associated with the blowing agent andthe thermoplastic composition.

A molding system can be utilized to prepare the disclosed foams thatincludes a device configured to receive a first thermoplasticcomposition and heat the first thermoplastic composition to form amolten first thermoplastic composition or a single-phase solution. Themolding system optionally can include a shot tuning chamber configuredto receive the molten first thermoplastic composition or thesingle-phase solution from the device and adjust a temperature of or apressure applied to the molten first thermoplastic composition or thesingle-phase solution. The molding system optionally can also include anadjustable mold runner configured to regulate the flow of the moltenfirst thermoplastic composition or the single-phase solution between theshot tuning chamber and a mold cavity. In one example, the device may bean injection device or an extrusion device. The molding system allowsthe characteristics of the first thermoplastic composition or thesingle-phase solution to be adapted to achieve desired end-use goals,such as, for example, to achieve a desired injection temperature or adesired foaming temperature or to achieve both.

In some aspects, the present disclosure is directed to a compressionmolded thermoplastic foam, and to a method of forming compression moldedthermoplastic foam for, among other applications, articles of footwearor athletic equipment. In some examples, the method can be a processcomprising providing (e.g., preparing) a thermoplastic foam preform andthen compression molding the thermoplastic foam preform to form acompression molded thermoplastic foam. For example, the thermoplasticfoam can be compression molded by placing the thermoplastic foam preformin a compression mold having a height less than the initial height ofthe thermoplastic foam preform and closing the mold, thereby compressingthe thermoplastic foam preform to the height of the mold. Simultaneouslyor sequentially with the compressing, the thermoplastic foam preform canbe heated in the closed compression mold. During the compressionmolding, the temperature of at least a portion of the thermoplastic foampreform in the closed mold can be raised to a temperature within ±30degrees centigrade of the softening temperature of the composition. Thetemperature can be raised by heating the closed mold. Following theraising of the temperature, while the thermoplastic foam preform remainsclosed in the compression mold, the temperature of at least a portion ofthe thermoplastic foam preform can be lowered. The temperature can belowered by cooling the closed mold. The lowering can lower thetemperature of at least a portion of the thermoplastic foam preform to atemperature at least 35 degrees centigrade below the softeningtemperature of the composition, thereby forming the compression moldedthermoplastic foam. Following the cooling, the compression mold can beopened, and the compression molded thermoplastic foam can be removedfrom the compression mold.

Examples contemplated herein are directed to methods of manufacturingarticles of footwear, apparel, or athletic equipment. For example, themethod can comprise providing components such as midsoles and inserts ofan article of footwear in accordance with the present disclosure, andcombining the component with a footwear upper and an outsole to form thearticle of footwear.

The thermoplastic foam can be made using a process that involvesimpregnating a first thermoplastic composition (e.g., at or above asoftening temperature of the composition) with a physical blowing agentat a first concentration or first pressure. The impregnated firstthermoplastic composition can then be foamed, or can be cooled (whenapplicable) and re-softened (when applicable) for blowing at a latertime. In some instances, the impregnated first thermoplastic compositionis foamed by reducing the temperature or pressure, impacting thesolubility of the physical blowing agent. The reduction in solubility ofthe physical blowing agent can release additional amounts of theimpregnated physical blowing agent from the first thermoplasticcomposition to further blow the composition forming a thermoplastic foam(e.g., a thermoplastic foam having a multicellular structure).

The thermoplastic foam can have a closed skin. A closed skin can beformed by foaming and molding a thermoplastic copolyester foam in aclosed mold. A closed skin can also be formed by compression molding athermoplastic foam preform in a compression mold. However, care shouldbe taken during the compression molding not to subject the thermoplasticfoam preform to conditions such that more than a desired amount of thecell structures of the foam collapse. One way to avoid collapsing morethan a desired amount of the cell structures is to control thetemperature of the thermoplastic foam during the compression moldingprocess, for example, by controlling the temperature of the mold. Forexample, during the compression molding step, the heating of thethermoplastic foam preform in the compression mold can be conducted fortime of from 100 seconds to 1,000 seconds, or of from 150 seconds to 700seconds.

Once the thermoplastic foam has been heated in the compression mold atthe appropriate temperature for the desired length of time to soften thethermoplastic foam to the desired level, the softened preform is cooled,for example, to a temperature at least 35 degrees centigrade below itssoftening temperature, or at least 50 degrees centigrade below itssoftening temperature, or at least 80 degrees centigrade below itssoftening temperature, to re-solidify the softened foam, thereby formingthe compression molded foam. Once cooled, the compression moldedthermoplastic foam is removed from the compression mold. Following theheating, the cooling of the foam preform in the compression mold can beconducted for a time of from 50 to 1,000 seconds, or for a time of from100 to 400 seconds.

The thermoplastic foam can be foamed using any one of the methodsdescribed above. The thermoplastic foam can be included in components ofarticles of footwear as described above, for example a midsole 146 asdepicted in FIGS. 1A-1B.

Methods of Manufacturing Disclosed Articles.

Various examples include methods of manufacturing an article comprisinga first component and a second component. As discussed herein above, thefirst component can be a foam component, e.g., a first foam component,and the second component can be a foam component, e.g., a second foamcomponent. The first component can be, but is not limited to, a midsoleor component of a midsole. The second component can be, but is notlimited to, an outsole or an upper. It is understood that the secondcomponent can be foamed, partially foamed, or essentially unfoamed. Insome instances, the second thermoplastic composition comprises one ormore disclosed thermoplastic elastomers. For example, a secondthermoplastic composition includes at least 90 weight percent, or atleast 95 weight percent, or at least 99 weight percent of thethermoplastic elastomer disclosed herein, based on the total weight ofthe second thermoplastic composition. In some instances, the secondthermoplastic composition includes a greater concentration of fillers,pigments or dyes as compared to the first thermoplastic composition ofthe first foam component. The disclosed methods of manufacturing anarticle comprising a first component and a second component may furthercomprise steps or adjustments as known to the skilled artisan.

In some aspects, the methods of manufacturing an article of footwearinclude injection molding a first thermoplastic composition to form athermoplastic foam described herein to produce a foam article orcomponent of an article, such as a cushioning element for an article offootwear. The methods can further comprise manufacturing an article orcomponent of an article comprising providing a midsole or a component ofa midsole, then providing an upper and/or an outsole or outsolecomponent for an article of footwear; and followed by combining themidsole or midsole component with the upper and/or the outsole oroutsole component to make an article of footwear. In some instances, themethod of manufacturing the article of footwear includes combining anarticle comprising a thermoplastic foam, an upper, and an outsole tomake an article of footwear. In various aspects, the upper and/oroutsole can comprise the same or a different thermoplastic composition,a second thermoplastic composition, or combinations thereof. In someinstances, the outsole used in the method can be foamed, partiallyfoamed, or substantially unfoamed. It is understood that a midsole,midsole component, outsole, or outsole component can be foamed orpartially foamed using the methods disclosed herein for the preparationof a foam article.

The various disclosed methods can include coupling a first component toa second component. In certain aspects, the disclosed methods compriseforming the first component and second component together. For example,the first thermoplastic composition for the first component, i.e., adisclosed thermoplastic composition, and the second thermoplasticcomposition can be added to a mold sequentially during an injectionmolding process to provide a unitary component having a first component,i.e., a foam portion comprising the first thermoplastic composition anda second component, e.g., a polymeric layer comprising the secondthermoplastic composition. In this aspect, a mold can be provided havinga first mold portion having a mold surface. The second thermoplasticcomposition can be added to the mold, so as to form a polymeric layer onat least a portion of the mold surface. The second thermoplasticcomposition can be added to the mold as a film or coating applied to amold surface. The process of adding the second thermoplastic compositioncan comprise injecting the second thermoplastic composition into themold cavity prior to injecting the first thermoplastic composition intothe mold cavity. Optionally, after injecting the second thermoplasticcomposition into the mold cavity but before injecting the firstthermoplastic composition into the mold cavity, the pressure within themold cavity, or the temperature of the mold cavity, or both, can bealtered. For example, after injecting the second thermoplasticcomposition into the mold, the pressure within the mold can be increasedin order to better cover the surfaces of the mold cavity with the secondthermoplastic composition and create a polymeric layer on the surfacesof the mold cavity. The first thermoplastic composition for the firstcomponent, i.e., a disclosed thermoplastic composition, can be injectedinto the mold containing the second component, i.e., the polymeric layercomprising the second thermoplastic composition, and foamed while incontact with the polymeric layer. The resultant injection-moldedcomponent is a unitary component, with the second component, i.e., thepolymeric layer, thermally bonded to the first component, i.e., the foamcomponent.

In one example, when injecting the second thermoplastic composition andthe first thermoplastic composition to form a unitary component asdescribed above, the second thermoplastic composition can be free ofblowing agents or essentially free of blowing agents, in order to form aunitary foamed article including an unfoamed polymer layer comprisingthe second thermoplastic composition covering the thermoplastic foamhaving a multicellular foam structure compositionally comprising thefirst thermoplastic composition. For example, the step of injecting thesecond thermoplastic composition can comprise injecting a molten secondthermoplastic composition that is free of or essentially free ofphysical or chemical blowing agents, and the step of injecting the firstthermoplastic composition can comprise injecting a single-phase solutionof the first thermoplastic composition and a supercritical fluid. Inthis way, the second thermoplastic composition can be used to form adecorative layer or a protective layer on the thermoplastic foam. Oneadvantage of this method is that the detail level of the unfoamedpolymeric layer can be greater, as an unfoamed material will retain agreater level of mold detail than a foamed layer. Another advantage ofthis method is that the second thermoplastic composition can havedifferent physical properties or coloration or both physical propertiesand coloration as compared to the first thermoplastic composition, orthe second thermoplastic composition and the first thermoplasticcomposition can be structurally different as described herein. Forexample, the second thermoplastic composition can have a greaterDurometer hardness, or a greater level of abrasion resistance, or agreater coefficient of friction in order to provide a greater level oftraction, as compared to the thermoplastic foam comprising the firstthermoplastic composition. In another example, the second thermoplasticcomposition can comprise a greater concentration of pigments or dyes orboth as compared to the first thermoplastic composition. For example,the second thermoplastic composition can comprise greater than 3 weightpercent, or greater than 4 weight percent, or greater than 5 weightpercent, or greater than 6 weight percent or greater than 10 weightpercent of pigments, while the first thermoplastic composition can befree of or essentially free of pigments. This can reduce the totalamount of pigments used to impart coloration to the unitary componentwithout the need to include pigments in both the first and secondthermoplastic compositions, which increases the recyclability of theunitary component.

Alternatively or additionally, the second component comprising thesecond thermoplastic composition can be disposed onto the exteriorsurface of the first component comprising the first thermoplasticcomposition during a compression molding step, or during a vacuumforming step. For example, a first component can be made such as byinjection molding, and the foam component can thereafter be compressionmolded or vacuum formed in a mold which includes the second component(optionally with heating), such that the first component bonds to thesurface of the second component during the compression molding or vacuumforming process. As described above, the second thermoplasticcomposition can have a greater Durometer hardness, or a greater level ofabrasion resistance, or a greater coefficient of friction in order toprovide a greater level of traction, as compared to the thermoplasticfoam comprising the first thermoplastic composition. The second and thefirst thermoplastic compositions can be structurally different. Inanother example, the second thermoplastic composition can comprise agreater concentration of pigments or dyes or both as compared to thefirst thermoplastic composition.

The second component can be provided as an already formed component,e.g., a second component, to the injection mold or compression mold. Forexample, the second component, e.g., a film, can be inserted into aninjection mold and held in place against a target surface of the moldvia vacuum ports, electrostatic charge or other method. The secondcomponent may be conformed to the target surface of the mold, forexample, with the application of heat or vacuum before or after it isinserted into the mold. The first thermoplastic composition for thefirst component, i.e., a disclosed thermoplastic copolyestercomposition, can then be injected into the mold containing the film, andfoamed as described herein. As a result the second component becomes anintegral part of the molded component.

Alternatively or additionally, the second component can be disposed ontothe foam component after the foam component has been formed. Accordingto some of the disclosed methods, the second component that is providedseparately from the first component, and are thereafter operably coupledso that the second component is in contact with a targeted portion of anexterior surface of the first component. The second component may becoupled with the exterior surface of a first component using anysuitable method. In an aspect, the second component may be adhesivelylaminated to the first component. In another aspect, the secondcomponent may be coupled with the first component may be thermallylaminated to an exterior surface of the first component. For example,heat may be applied to an exterior surface of the first component, to asurface of the second component, or both, to soften or melt the heatedsurface(s), and the two surfaces may be joined when one or both are inthe softened or melted state. In an aspect, the second component may becoupled with the first component using a flame lamination process.

The second component can be provided as a polymeric layer. For example,a polymeric coating can be formed by applying a liquid secondthermoplastic composition onto the foam component, such as by spraying,dip coating, tumble-coating, brushing, or a combination thereof. Theliquid polymeric material can then be dried or cured while in contactwith the first component.

The polymeric layer can be disposed on at least one exterior surface ofthe foam component. For example, where the foam article is a midsole,the coating can be on all or part of the sidewall of the midsole, or onall or part of a ground-facing (bottom) surface of the midsole, or onall or part of an upper-facing (top) surface of the midsole, or anycombination thereof. The polymeric layer can be disposed on at least onesurface that may be exposed to moisture during normal use of thefinished article, e.g., an article of footwear.

As disposed on the foam component, the polymeric layer has an averagethickness of about 0.01 millimeter to about 3 millimeter, or about 0.03millimeter to about 2 millimeter, or from about 0.1 millimeter to about1 millimeter.

According to various aspect, the foam component or article having thedisclosed polymeric layer has similar physical properties when comparedto an equivalent foam component or article that lacks the polymericlayer.

In a particular aspect, when the second thermoplastic composition is afilm, the film can be a multi-layer film. The multi-layer film caninclude one or more layers of the second thermoplastic composition, andone or more layers of a different (i.e., third) thermoplasticcomposition. The third thermoplastic composition can be a materialhaving a lower level of oxygen transmission or water vapor transmissionor both, as compared to the second thermoplastic composition. Forexample, the third thermoplastic composition can comprise a barrierpolymer such as ethylene-vinyl alcohol (EVOH). One example of amulti-layer film includes a first layer comprising a secondthermoplastic composition including TPU, and a second layer comprising athird thermoplastic composition including EVOH. Alternatively, the thirdthermoplastic composition can be an adhesive layer comprising one ormore adhesive polymers, such as one or more hot melt adhesive polymers.Another example of a multi-layer film includes a first layer comprisinga second thermoplastic composition including a first TPU, and a secondlayer comprising a third thermoplastic composition including a secondhot melt adhesive TPU having a lower melting temperature than the firstTPU.

The polymeric layer can be formed by applying a powdered secondthermoplastic composition onto the foam component, such as by spraying,powder-coating, electrostatically coating, tumble-coating, or acombination thereof. In some aspects, an adhesive could be used to affixthe powder to the midsole, and/or a coating can be applied over thepowder to hold it in place on the foam component. Once the powder isaffixed to the midsole, it can be left in the form of a powder, or itcan be treated so as to form a more uniform coating, such as by heatingit to melt it, by applying a solvent to solubilize it, etc.

Alternatively, the polymeric layer can take the form of a separateelement which is applied to all or a portion of an exterior surface ofthe foam component when incorporating the midsole into an article offootwear. For example, the foam component can be a midsole component ofan article of footwear, and the polymeric layer can be a rand or foxingtape applied around a perimeter of the midsole. The polymeric layer canbe an extension of an outsole covering all or a portion of the bottomsurface of the midsole, and which wraps up and covers at least a portionof the sidewall of the midsole. The polymeric layer can be the “shell”portion of a core-shell sole structure, which covers both the bottomsurface and the sidewalls of the midsole, and which is attached to theupper of the article of footwear.

The foam articles and components can be foamed using any one of themethods described above.

In various aspects, the disclosed methods of manufacturing articlescomprising a first component and a second component, the secondcomponent comprising a second thermoplastic composition can be producedseparately via injection molding with or without the addition ofcompressed gas, supercritical fluids or other blowing agents upon whichthe foam article is produced.

In some instances, the disclosed methods of manufacturing articlescomprising a first component and a second component comprise injectionvia overmolding. In some instances, overmolding can comprise sequentialinjection of a polymeric material for the first component, i.e., adisclosed thermoplastic copolyester, and a second thermoplasticcomposition in the same process, or wherein the second thermoplasticcomposition was produced in a separate process, and subsequentlyinserted into the mold after which foam article from the firstthermoplastic composition is over molded. The second component can beproduced separately via injection molding with only sufficientcompressed gas, supercritical fluids or other blowing agents to achievea density of 0.90 grams per cubic centimeter, 0.85 grams per cubiccentimeter, or 0.80 grams per cubic centimeter.

In some instances, the disclosed methods of manufacturing articlescomprising a first component and a second component comprise a step ofcorona treatment. That is, for example, the second component can be afilm or an outsole or a rand that is pretreated with a plasma or coronatreatment prior to receiving the overmolding assembly described herein.

In some instances, the disclosed methods of manufacturing articlescomprising a first component and a second component comprise a step ofpretreatment with a primer. That is, for example, the second componentcan be a film or an outsole or a rand that is pretreated with a primeralone, or a primer plus and an adhesive prior to receiving theovermolding assembly method described herein.

In some instances, the disclosed methods of manufacturing articlescomprising a first component and a second component comprise a step offused deposition 3D printing. That is, for example, the second componentcan be fused deposition 3D printed onto a first component. In suchinstances, a second thermoplastic composition can be extruded into afused deposition 3D printing filament of about 1.5 mm, about 1.75 mm,about 1.85 mm, about 2.85 mm, about 3.0 mm, or other relevant diameterfor deposition and attachment to first component in such a way that itcomprises the ground contact layer, print-on outsole, or other exteriorfeatures. Any grade commonly used in injection molding will typicallysuffice for 3D print filament for fused deposition applications.

The resulting article comprising the first and second components can becharacterized by good bonding strength between the first and the secondcomponents. The ply adhesion strength between the polymeric layer andthe foam component is greater than 2.5 kg force/centimeter or greaterthan 3.0 kg force/centimeter, when determined using the Ply AdhesionTest method described herein. Alternatively additionally, the bondingstrength between the first and the second components can be determinedaccording to the Hand Pull Test, described herein. The disclosedarticles or components can have a bond between the first and the secondcomponents that has an average hand pull test result of greater than orequal to 2.0, or greater than or equal to 2.5, or greater than or equalto 3.0, or greater than or equal to 3.5, or greater than or equal to4.0, or greater than or equal to 4.5, when determined according to theHand Pull Test method described herein.

Each of the first and/or the second components can be characterized byone or more properties. For example, a first and/or a second componentcan have an Akron abrasion of less than 0.50 cubic centimeters lost,optionally less than 0.40 cubic centimeters lost, less than 0.30 cubiccentimeters lost, less than 0.20 cubic centimeters lost, or less than0.10 cubic centimeters lost as determined using the Akron Abrasion Test.The first and/or the second components can have an Akron abrasion ofabout 0.05 cubic centimeters lost, about 0.10 cubic centimeters lost,about 0.15 cubic centimeters lost, about 0.20 cubic centimeters lost,about 0.25 cubic centimeters lost, about 0.30 cubic centimeters lost,about 0.35 cubic centimeters lost, about 0.40 cubic centimeters lost,about 0.45 cubic centimeters lost, or about 0.50 cubic centimeters lostas determined using the Akron Abrasion Test, any range of abrasionvalues encompassed by any of the foregoing values, or any combination ofthe foregoing abrasion values.

The first and/or a second component can have an Akron abrasion of lessthan 500 milligrams lost, optionally less than 400 milligrams lost, lessthan 300 milligrams lost, less than 200 milligrams lost, or less than100 milligrams lost as determined using the Akron Abrasion Test. Thefirst and/or a second component can have an can have an Akron abrasionof about 50 milligrams lost, about 100 milligrams lost, about 150milligrams lost, about 200 milligrams lost, about 250 milligrams lost,about 300 milligrams lost, about 350 milligrams lost, about 400milligrams lost, about 450 milligrams lost, or about 500 milligrams lostas determined using the Akron Abrasion Test, any range of abrasionvalues encompassed by any of the foregoing values, or any combination ofthe foregoing abrasion values.

The first and/or a second component can have a DIN abrasion of less than0.30 cubic centimeters lost, optionally less than 0.20 cubic centimeterslost, less than 0.10 cubic centimeters lost, less than 0.05 cubiccentimeters lost, or less than 0.03 cubic centimeters lost as determinedusing the DIN Abrasion Test. The first and/or a second component canhave a DIN abrasion of about 0.01 cubic centimeters lost, about 0.05cubic centimeters lost, about 0.10 cubic centimeters lost, about 0.15cubic centimeters lost, about 0.20 cubic centimeters lost, about 0.25cubic centimeters lost, or about 0.30 cubic centimeters lost asdetermined using the DIN Abrasion Test, any range of abrasion valuesencompassed by any of the foregoing values, or any combination of theforegoing abrasion values.

The first and/or a second component can have a DIN abrasion of less than300 milligrams lost, optionally less than 250 milligrams lost,optionally less than 200 milligrams lost, optionally less than 150milligrams lost, optionally less than 100 milligrams lost, optionallyless than 80 milligrams lost, optionally less than 50 milligrams lost,or optionally less than 30 milligrams as determined using the DINAbrasion Test. The first and/or a second component can have a DINabrasion of about 10 milligrams lost, about 50 milligrams lost, about100 milligrams lost, about 150 milligrams lost, about 200 milligramslost, about 250 milligrams lost, or about 300 milligrams lost asdetermined using the DIN Abrasion Test, any range of abrasion valuesencompassed by any of the foregoing values, or any combination of theforegoing abrasion values.

The first and/or a second component described herein when incorporatedinto an article the product can have improved traction properties. Inone aspect, the coefficient of friction of the polymer layer can be usedto measure traction properties.

The first and/or a second component can have a dry dynamic coefficientof friction (COF) on a dry surface (e.g., a smooth, flat, or texturedsurface such as, for example, wooden parquet court, concrete, asphalt,laminate, brick, or ceramic tile) of greater than 0.5, optionally ofgreater than 0.7, greater than 0.8, greater than 0.9, greater than 1.0,as determined using the Dry Outsole Coefficient of Friction Test. Thepolymer layer can have a dry dynamic COF of greater than 0.15,optionally of greater than 0.2, greater than 0.25, or greater than 0.3,using the Dry Upper Coefficient of Friction Test.

The first and/or a second component can have a wet dynamic COF ofgreater than 0.25, optionally of greater than 0.30, greater than 0.35,greater than 0.40, or greater than 0.50, as determined using the WetOutsole Coefficient of Friction Test. The polymer layer can have a wetdynamic COF of greater than 0.15, optionally of greater than 0.2,greater than 0.25, or greater than 0.3, using the Wet Upper Coefficientof Friction Test.

It may be desirable for the dynamic coefficient of friction for the samedry and wet surface (e.g., smooth concrete or court) to be as close aspossible. In one aspect, the difference between the dynamic coefficientof friction of the dry surface and the wet surface is less than 15percent. In another aspect, the difference between the dynamiccoefficient of friction of the dry surface and the wet surface is about0 percent, about 1 percent, about 2 percent, about 3 percent, about 4percent, about 5 percent, about 6 percent, about 7 percent, about 8percent, about 9 percent, about 10 percent, about 11 percent, about 12percent, about 13 percent, about 14 percent, or about 15 percent, anyrange of percentage values encompassed by any of the foregoing values,or any combination of the foregoing percentage values.

The first and/or a second component can have a durometer Shore Ahardness of less than 90 or less than 85 or less than 80. The polymerlayer can have a durometer Shore A hardness of greater than 60 orgreater than 65. The polymer layer can have a durometer Shore A hardnessof about 50 to about 90 Shore A, optionally from about 55 to about 85Shore A, from about 60 to about 80 Shore A, or from about 60 to about 70Shore A. The polymer layer can have a durometer Shore A hardness ofabout 50 A, about 55 A, about 60 A, about 65 A, about 70 A, about 75 A,about 80 A, about 85 A, or about 90 A, any range of Shore A hardnessvalues encompassed by any of the foregoing values, or any combination ofthe foregoing Shore A hardness values.

Thermoplastic Copolyester Composition

The thermoplastic compositions disclosed herein (i.e., the polymericmaterial for the first component of the foam portion and/or the secondthermoplastic composition) can include or consist essentially of one ormore thermoplastic copolyesters, including one or more thermoplasticcopolyester elastomers. In some aspects, the first thermoplasticcomposition for the first component includes at least 90 percent or atleast 95 weight percent, or at least 99 weight percent of athermoplastic copolyester disclosed herein, based on the total weight ofthe first thermoplastic composition.

The thermoplastic copolyester compositions include or consistessentially of one or more thermoplastic copolyesters. The disclosedthermoplastic copolyester composition can include at least about 90weight percent or at least about 95 weight percent or at least about 99weight percent of the one or more thermoplastic copolyesters, based onthe total weight of the thermoplastic copolyester composition. In someaspects, the polymeric component of the thermoplastic copolyestercomposition, which is comprised of all the polymeric materials presentin the thermoplastic copolyester composition, consists essentially ofthe one or more thermoplastic copolyesters. The thermoplasticcopolyesters can include chain units derived from one or more olefinsand chain units derived from one or more ethylenically-unsaturated acidgroups.

The thermoplastic copolyester compositions can have a melt flow index offrom about 5 to about 40, or about 10 to about 20, or about 20 to about30 as determined at 210 degrees centigrade using a 2.16 kilogram weight.Alternatively or additionally, the thermoplastic copolyestercompositions can have a melt flow index of from about 5 to about 40, orabout 10 about 20, or about 20 to about 30 as determined at 220 degreescentigrade using a 2.16 kilogram weight. Alternatively or additionally,the thermoplastic copolyester compositions can have a melt flow index offrom about 5 to about 40, or about 10 to about 20, or about 20 to about30 as determined at 230 degrees centigrade using a 2.16 kilogram weight.

The thermoplastic copolyesters can be terpolymers of moieties derivedfrom ethylene, acrylic acid, and methyl acrylate or butyl acrylate. Insome aspects, a ratio of a total parts by weight of the acrylic acid inthe thermoplastic copolyesters to a total weight of the thermoplasticcopolyesters is about 0.05 to about 0.6, about 0.1 to about 0.6, about0.1 to about 0.5, about 0.15 to about 0.5, or about 0.2 to about 0.5.

The thermoplastic compositions provided herein can include athermoplastic copolyester comprising: (a) a plurality of first segments,each first segment derived from a dihydroxy-terminated polydiol; (b) aplurality of second segments, each second segment derived from a diol;and (c) a plurality of third segments, each third segment derived froman aromatic dicarboxylic acid. In various aspects, the thermoplasticcopolyester is a block copolymer. In some aspects, the thermoplasticcopolyester is a segmented copolymer. In further aspects, thethermoplastic copolyester is a random copolymer. In still furtheraspects, the thermoplastic copolyester is a condensation copolymer.

The thermoplastic copolyester can have a weight average molecular weightof about 50,000 Daltons to about 1,000,000 Daltons; about 50,000 Daltonsto about 500,000 Daltons; about 75,000 Daltons to about 300,000 Daltons;about 100,000 Daltons to about 250,000 Daltons; about 100,000 Dalton toabout 500,000 Dalton; or a value or values of weight average molecularweight within any of the foregoing ranges or a weight average molecularweight range encompassing any sub-range of the foregoing ranges.

The thermoplastic copolyester can have a ratio of first segments tothird segments from about 1:1 to about 1:5 based on the weight of eachof the first segments and the third segments; about 1:1 to about 1:3based on the weight of each of the first segments and the thirdsegments; about 1:1 to about 1:2 based on the weight of each of thefirst segments and the third segments; about 1:1 to about 1:3 based onthe weight of each of the first segments and the third segments; or avalue or values of have a ratio of first segments to third segmentswithin any of the foregoing ranges or a have a range of ratio of firstsegments to third segments encompassing any sub-range of the foregoingranges.

The thermoplastic copolyester can a ratio of second segments to thirdsegments from about 1:1 to about 1:2 based on the weight of each of thefirst segments and the third segments; about 1:1 to about 1:1.52 basedon the weight of each of the first segments and the third segment; or avalue or values of have a ratio of second segments to third segmentswithin any of the foregoing ranges or a have a range of ratio of secondsegments to third segments encompassing any sub-range of the foregoingranges.

The thermoplastic copolyester can have first segments derived from apoly(alkylene oxide)diol having a number-average molecular weight ofabout 250 Daltons to about 6000 Daltons; about 400 Daltons to about6,000 Daltons; about 350 Daltons to about 5,000 Daltons; about 500Daltons to about 3,000 Daltons; about 2,000 Daltons to about 3,000Daltons; or a value or values of weight average molecular weight withinany of the foregoing ranges or a weight average molecular weight rangeencompassing any sub-range of the foregoing ranges.

The thermoplastic copolyester can have first segments derived from apoly(alkylene oxide)diol such as poly(ethylene ether)diol;poly(propylene ether)diol; poly(tetramethylene ether)diol;poly(pentamethylene ether)diol; poly(hexamethylene ether)diol;poly(heptamethylene ether)diol; poly(octamethylene ether)diol;poly(nonamethylene ether)diol; poly(decamethylene ether)diol; ormixtures thereof. In a still further aspect, the thermoplasticcopolyester can have first segments derived from a poly(alkyleneoxide)diol such as poly(ethylene ether)diol; poly(propylene ether)diol;poly(tetramethylene ether)diol; poly(pentamethylene ether)diol;poly(hexamethylene ether)diol. In a yet further aspect, thethermoplastic copolyester can have first segments derived from apoly(tetramethylene ether)diol.

The thermoplastic copolyester can have second segments derived from adiol having a molecular weight of less than about 250. The diol fromwhich the second segments are derived can be a C2-C8 diol. In a stillfurther aspect, the second segments can be derived from ethanediol;propanediol; butanediol; pentanediol; 2-methyl propanediol; 2,2-dimethylpropanediol; hexanediol; 1,2-dihydroxy cyclohexane; 1,3-dihydroxycyclohexane; 1,4-dihydroxy cyclohexane; and mixtures thereof. In a yetfurther aspect, the second segments can be derived from 1,2-ethanediol,1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and mixtures thereof.In an even further aspect, the second segments can be derived from1,2-ethanediol. In a still further aspect, the second segments can bederived from 1,4-butanediol.

The thermoplastic copolyester can have third segments derived from anaromatic C5-C16 dicarboxylic acid. The aromatic C5-C16 dicarboxylic acidcan have a molecular weight less than about 300 Daltons; about 120Daltons to about 200 Daltons; or a value or values of molecular weightwithin any of the foregoing ranges or a molecular weight rangeencompassing any sub-range of the foregoing ranges. In some instances,the aromatic C5-C16 dicarboxylic acid is terephthalic acid, phthalicacid, isophthalic acid, or a derivative thereof. In a still furtheraspect, the aromatic C5-C16 dicarboxylic acid is a diester derivative ofthe terephthalic acid, phthalic acid, or isophthalic acid. In a yetfurther aspect, the aromatic C5-C16 dicarboxylic acid is terephthalicacid or the dimethyl ester derivative thereof.

The thermoplastic copolyester can comprise: (a) a plurality of firstcopolyester units, each first copolyester unit of the pluralitycomprising the first segment derived from a dihydroxy-terminatedpolydiol and the third segment derived from an aromatic dicarboxylicacid, wherein the first copolyester unit has a structure represented bya Formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide) diol of the first segment, whereinthe poly(alkylene oxide) diol of the first segment is a poly(alkyleneoxide) diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and (b) a plurality of second copolyester units, each secondcopolyester unit of the plurality comprising the second segment derivedfrom a diol and the third segment derived from an aromatic dicarboxylicacid, wherein the second copolyester unit has a structure represented bya Formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.

The thermoplastic copolyester can comprise a plurality of firstcopolyester units having a structure represented by a Formula 3:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be is an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, the foregoing formula, zis an integer having a value from 5 to 60; an integer having a valuefrom 5 to 50; an integer having a value from 5 to 40; an integer havinga value from 4 to 30; an integer having a value from 4 to 20; an integerhaving a value from 2 to 10; or z can be any set or range of theforegoing integer values. In some aspects, R is hydrogen. In a stillfurther aspect, R is methyl. In some instances, R is hydrogen and y isan integer having a value of 1, 2, or 3. Alternatively, in otherinstances, R is methyl and y is an integer having a value of 1.

The thermoplastic copolyester can comprise a plurality of firstcopolyester units having a structure represented by a Formula 4:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be is an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, the foregoing formula, zis an integer having a value from 5 to 60; an integer having a valuefrom 5 to 50; an integer having a value from 5 to 40; an integer havinga value from 4 to 30; an integer having a value from 4 to 20; an integerhaving a value from 2 to 10; or z can be any integer value or set ofinteger values within the foregoing ranges or values, or any range ofinteger values encompassing a sub-range the foregoing integer valueranges.

The thermoplastic copolyester can comprise a plurality of firstcopolyester units having a weight average molecular weight from about400 Daltons to about 6,000 Daltons; about 400 Daltons to about 5,000Daltons; about 400 Daltons to about 4,000 Daltons; about 400 Daltons toabout 3,000 Daltons; about 500 Daltons to about 6,000 Daltons; about 500Daltons to about 5,000 Daltons; about 500 Daltons to about 4,000Daltons; about 500 Daltons to about 3,000 Daltons; about 600 Daltons toabout 6,000 Daltons; about 600 Daltons to about 5,000 Daltons; about 600Daltons to about 4,000 Daltons; about 600 Daltons to about 3,000Daltons; about 2,000 Daltons to about 3,000 Daltons; or a value orvalues of weight average molecular weight within any of the foregoingranges or a weight average molecular weight range encompassing anysub-range of the foregoing ranges.

The thermoplastic copolyester can comprise a plurality of secondcopolyester units, each second copolyester unit of the plurality havingrepresented by a Formula 5:

wherein x is an integer having a value from 1 to 20; wherein the foamarticle has a multicellular closed-cell or open-cell foam structure. Insome aspects, in the foregoing formula, x is an integer having a valuefrom 2 to 18; 2 to 17; 2 to 16; 2 to 15; 2 to 14; 2 to 13; 2 to 12; 2 to11; 2 to 10; 2 to 9; 2 to 8; 2 to 7; 2 to 6; 2 to 5; 2 to 4; or x can beany integer value or set of integer values within the foregoing rangesor values, or any range of integer values encompassing a sub-range theforegoing integer value ranges. In a further aspect, x is an integerhaving a value of 2, 3, or 4.

The thermoplastic copolyester can comprise a plurality of secondcopolyester units, each second copolyester unit of the plurality havingrepresented by a Formula 6:

The thermoplastic copolyester can comprise a weight percent range of theplurality of first copolyester units based on total weight of thethermoplastic copolyester such that the weight percent range is about 30weight percent to about 80 weight percent; about 40 weight percent toabout 80 weight percent; about 50 weight percent to about 80 weightpercent; about 30 weight percent to about 70 weight percent; about 40weight percent to about 70 weight percent; about 50 weight percent toabout 70 weight percent; about 40 weight percent to about 65 weightpercent; about 45 weight percent to about 65 weight percent; about 50weight percent to about 65 wt; about 55 weight percent to about 65weight percent; about 40 weight percent to about 60 weight percent;about 45 weight percent to about 60 weight percent; about 50 weightpercent to about 60 weight percent; about 55 weight percent to about 60weight percent; or any weight percent value or set of weight percentvalues within any of the foregoing ranges of weight percent, or anyrange of weight percent values encompassing a sub-set of any of theforegoing ranges.

In some aspects, when in solid form, the thermoplastic copolyester cancomprise phase separated domains. For example, a plurality of firstsegments derived from a dihydroxy-terminated polydiol can phase-separateinto domains comprising primarily the first segments. Moreover, aplurality of second segments derived from a diol can phase-separate intodomains comprising primarily the second segments. In other aspects, thethermoplastic copolyester can comprise phase-separated domainscomprising primarily of a plurality of first copolyester units, eachfirst copolyester unit of the plurality comprising the first segmentderived from a dihydroxy-terminated polydiol and the third segmentderived from an aromatic dicarboxylic acid, wherein the firstcopolyester unit has a structure represented by a Formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide) diol of the first segment, whereinthe poly(alkylene oxide) diol of the first segment is a poly(alkyleneoxide) diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and other phase-separated domains comprising primarily of aplurality of second copolyester units, each second copolyester unit ofthe plurality comprising the second segment derived from a diol and thethird segment derived from an aromatic dicarboxylic acid, wherein thesecond copolyester unit has a structure represented by a Formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.

In other aspects, when in solid form, the thermoplastic copolyester cancomprise phase-separated domains comprising primarily of a plurality offirst copolyester units, each first copolyester unit of the pluralityhaving a structure represented by a Formula 3:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be is an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, the foregoing formula, zis an integer having a value from 5 to 60; an integer having a valuefrom 5 to 50; an integer having a value from 5 to 40; an integer havinga value from 4 to 30; an integer having a value from 4 to 20; an integerhaving a value from 2 to 10; or z can be any set or range of theforegoing integer values. In some aspects, R is hydrogen. In a stillfurther aspect, R is methyl. In some instances, R is hydrogen and y isan integer having a value of 1, 2, or 3. Alternatively, in otherinstances, R is methyl and y is an integer having a value of 1.

In other aspects, when in solid form, the thermoplastic copolyester cancomprise phase-separated domains comprising primarily of a plurality offirst copolyester units, each first copolyester unit of the pluralityhaving a structure represented by a Formula 4:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be is an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, the foregoing formula, zis an integer having a value from 5 to 60; an integer having a valuefrom 5 to 50; an integer having a value from 5 to 40; an integer havinga value from 4 to 30; an integer having a value from 4 to 20; an integerhaving a value from 2 to 10; or z can be any integer value or set ofinteger values within the foregoing ranges or values, or any range ofinteger values encompassing a sub-range the foregoing integer valueranges.

When in solid form, the thermoplastic copolyester can comprisephase-separated domains comprising primarily of a plurality of firstcopolyester units having a weight average molecular weight from about400 Daltons to about 6,000 Daltons; about 400 Daltons to about 5,000Daltons; about 400 Daltons to about 4,000 Daltons; about 400 Daltons toabout 3,000 Daltons; about 500 Daltons to about 6,000 Daltons; about 500Daltons to about 5,000 Daltons; about 500 Daltons to about 4,000Daltons; about 500 Daltons to about 3,000 Daltons; about 600 Daltons toabout 6,000 Daltons; about 600 Daltons to about 5,000 Daltons; about 600Daltons to about 4,000 Daltons; about 600 Daltons to about 3,000Daltons; about 2,000 Daltons to about 3,000 Daltons; or a value orvalues of weight average molecular weight within any of the foregoingranges or a weight average molecular weight range encompassing anysub-range of the foregoing ranges.

In other aspects, when in solid form, the thermoplastic copolyester cancomprise phase-separated domains comprising a plurality of secondcopolyester units, each second copolyester unit of the plurality havingrepresented by a Formula 5:

wherein x is an integer having a value from 1 to 20; wherein the foamarticle has a multicellular closed-cell or open-cell foam structure. Insome aspects, in the foregoing formula, x is an integer having a valuefrom 2 to 18; 2 to 17; 2 to 16; 2 to 15; 2 to 14; 2 to 13; 2 to 12; 2 to11; 2 to 10; 2 to 9; 2 to 8; 2 to 7; 2 to 6; 2 to 5; 2 to 4; or x can beany integer value or set of integer values within the foregoing rangesor values, or any range of integer values encompassing a sub-range theforegoing integer value ranges. In a further aspect, x is an integerhaving a value of 2, 3, or 4.

In other aspects, when in solid form, the thermoplastic copolyester cancomprise phase-separated domains comprising a plurality of secondcopolyester units, each second copolyester unit of the plurality havingrepresented by a Formula 6:

When in solid form, the thermoplastic copolyester can comprisephase-separated domains comprising a weight percent range of theplurality of first copolyester units based on total weight of thethermoplastic copolyester such that the weight percent range is about 30weight percent to about 80 weight percent; about 40 weight percent toabout 80 weight percent; about 50 weight percent to about 80 weightpercent; about 30 weight percent to about 70 weight percent; about 40weight percent to about 70 weight percent; about 50 weight percent toabout 70 weight percent; about 40 weight percent to about 65 weightpercent; about 45 weight percent to about 65 weight percent; about 50weight percent to about 65 wt; about 55 weight percent to about 65weight percent; about 40 weight percent to about 60 weight percent;about 45 weight percent to about 60 weight percent; about 50 weightpercent to about 60 weight percent; about 55 weight percent to about 60weight percent; or any weight percent value or set of weight percentvalues within any of the foregoing ranges of weight percent, or anyrange of weight percent values encompassing a sub-set of any of theforegoing ranges.

The disclosed thermoplastic copolyester composition, the polymericcomponent of the composition or an individual thermoplastic copolyestercopolymer in neat form can be characterized by one or more properties.In some aspects, the thermoplastic copolyester composition or thepolymeric component, or the polymer has a maximum load of about 10newtons to about 100 newtons, or from about 15 newtons to about 50newtons, or from about 20 newtons to about 40 newtons; or any load valueor set of load values within any of the foregoing ranges of load value,or any range of load values encompassing a sub-set of any of theforegoing ranges, when determined using the Cyclic Tensile Test methoddescribed herein.

The tensile strength of the thermoplastic copolyester composition or ofthe component of the thermoplastic copolyester composition or of athermoplastic copolyester copolymer in neat form is another importantphysical characteristic. The thermoplastic copolyester composition orcomponent or copolymer can have a tensile strength of from 5 kilogramsper square centimeter to 25 kilograms per square centimeter, or of from10 kilograms per square centimeter to 23 kilograms per squarecentimeter, or of from 15 kilograms per square centimeter to 22kilograms per square centimeter; or any load value or set of load valueswithin any of the foregoing ranges of load value, or any range of loadvalues encompassing a sub-set of any of the foregoing ranges, whendetermined using the Cyclic Tensile Test method described herein.

The thermoplastic copolyester composition or polymeric component of thethermoplastic copolyester composition or a thermoplastic copolyestercopolymer in neat form can have a tensile modulus of about 2 megapascalsto about 20 megapascals or from about 5 megapascals to about 15megapascals when determined using the Cyclic Tensile Test methoddescribed herein; or any load value or set of load values within any ofthe foregoing ranges of load value, or any range of load valuesencompassing a sub-set of any of the foregoing ranges.

Exemplary, but non-limiting, thermoplastic polyester elastomers,including thermoplastic copolyesters, that can be used in the disclosedmethods, foams, and articles include “HYTREL” 3078, “HYTREL” 4068, and“HYTREL” 4556 (DuPont, Wilmington, Del., USA); “PELPRENE” P30B, P40B,and P40H (Toyobo U.S.A. Inc., New York, N.Y., USA); “TRIEL” 5300,“TRIEL” 5400, and blends thereof (Samyang Corporation, Korea); “KEYFLEX”BT1028D, BT1033D, BT1035D, BT1040D, BT1045D, and BT1047D (LG Chem,Korea); and “KOPEL” KP3340, KP3346, KP3347, KP3942 (Kolon Plastics,Inc., Korea).

The disclosed thermoplastic copolyester compositions can further includeone or more ionomers, such as any of the “SURLYN” polymers (DuPont,Wilmington, Del., USA). Ionic foams described herein can be made by aprocess/method including receiving a composition described herein, andphysically foaming the composition to form a thermoplastic copolyesterfoam having a density of about 0.7 gram per cubic centimeter or less, or0.5 gram per cubic centimeter or less, or 0.4 gram per cubic centimeteror less, or 0.3 gram per cubic centimeter or less. The process caninclude blowing the composition to produce an article or componentcomprising the thermoplastic copolyester foam. In some examples, theprocess for forming the thermoplastic copolyester foam comprisesinjection molding a mixture including a composition as described hereinand a supercritical fluid (e.g., supercritical carbon dioxide orsupercritical nitrogen) in a mold, and removing the thermoplasticcopolyester foam from the mold.

The disclosed thermoplastic copolyester compositions can further includeone or more thermoplastic polyurethanes, including thermoplasticpolyurethane elastomers, such as “FORTIMO” (Mitsui Chemicals, Inc.,Tokyo, Japan); “TEXIN” (Covestro LLC, Pittsburgh, Pa., USA); and“BOUNCELL-X” (Lubrizol Advanced Materials, Inc., Brecksville, Ohio,USA).

The disclosed thermoplastic copolyester compositions can further includeone or more olefinic polymers. Olefinic polymers can includeethylene-based copolymers, propylene-based copolymers, and butene-basedcopolymers. In some aspects, the olefinic polymer is an ethylene-basedcopolymer such as a styrene-ethylene/butylene-styrene (SEBS) copolymer;an ethylene-propylene diene monomer (EPDM) copolymer; an ethylene-vinylacetate (EVA) copolymer; an ethylene alkyl acrylate (EAA) copolymer; anethylene alkyl methacrylate (EAMA) copolymer; any copolymer thereof, andany blend thereof. In some aspects, a ratio V of a total parts by weightof the olefinic polymers present in the composition to a total parts byweight of the thermoplastic copolyesters in the composition is about 0.0to about 0.6, about 0.0 to about 0.4, about 0.01 to about 0.4, or about0.01 to about 0.6, or about 0.1 to about 0.4.

The disclosed thermoplastic copolyester compositions can further includean ethylene-vinyl acetate (EVA) copolymer. The ethylene-vinyl acetate(EVA) copolymer can have a range of vinyl acetate contents, for exampleabout 50 percent to about 90 percent, about 50 percent to about 80percent, about 5 percent to about 50 percent, about 10 percent to about45 percent, about 10 percent to about 30 percent, about 30 percent toabout 45 percent, or about 20 percent to about 35 percent, based on atotal weight of the copolymer.

The disclosed thermoplastic copolyester compositions can further includean ethylene-vinyl alcohol (EVOH) copolymer. The EVOH copolymer can havea range of vinyl alcohol contents, for example about 50 percent to about90 percent, about 50 percent to about 80 percent, about 5 percent toabout 50 percent, about 10 percent to about 45 percent, about 10 percentto about 30 percent, about 30 percent to about 45 percent, or about 20percent to about 35 percent, based on a total weight of the copolymer.

Second Thermoplastic Compositions

Having described the foams and methods of forming them, we turn to thesecond thermoplastic composition. According to the various aspects, thedisclosed foam article has a second thermoplastic composition disposedon at least one exterior surface of the foam. For example, the secondthermoplastic composition can be a polymeric layer or a polymericcoating or a polymeric film. In some aspects, the second thermoplasticcomposition has a higher abrasion resistance than the foam component. Inanother aspect, the second thermoplastic composition has a highercoefficient of friction than the first thermoplastic composition of thefoam component. In another aspect, the second thermoplastic compositionhas a higher Durometer hardness than the foam component. In otheraspects, the second thermoplastic composition has a higher specificgravity than the foam component. In other aspect, the secondthermoplastic composition comprises a higher concentration ofnon-polymeric ingredients, such as fillers and pigments, than the firstthermoplastic composition of the foam component. In yet another aspect,the second thermoplastic composition has two or more of a higherabrasion resistance, a higher coefficient of friction, a higherDurometer hardness, a higher specific gravity, and a higherconcentration of non-polymeric ingredients, as compared to the foamcomponent or the first thermoplastic composition of the foam component.In one aspect, the second thermoplastic composition is structurallydifferent than the first thermoplastic composition as described below.Alternatively, the second thermoplastic composition is structurally thesame as the first thermoplastic composition. The second thermoplasticcomposition may be integral with the foam component, or may be aseparate component that is operably coupled with the foam component, asdescribed herein.

In one aspect, the first thermoplastic composition can be structurallythe same as or structurally different from the second thermoplasticcomposition. Here, the first thermoplastic composition has one or morestructural chemical features that are the same as or different than thesecond thermoplastic composition. In one aspect, the structuraldifference is based on the chemical structure of the first thermoplasticelastomer being different from the chemical structure of all of thesecond thermoplastic elastomers present in the second thermoplasticcomposition (e.g., different positional or stereochemical groups). Inanother aspect, the structural difference is based on a number-averagemolecular weight of the first thermoplastic elastomer being differentfrom a number-average molecular weight of second thermoplasticelastomer, where the first and second thermoplastic elastomers have thesame chemical structure. In another aspect, the first structuraldifference is based on a concentration of the first thermoplasticelastomer in the first thermoplastic composition being different from aconcentration of the second thermoplastic elastomer in the secondthermoplastic composition, where the first and second thermoplasticelastomers have the same chemical structure and the same number averagemolecular weights. In yet another aspect, the structural difference isbased on any combination of the chemical structure, the number-averagemolecular weight, and the concentration being different. For example, afirst thermoplastic composition comprising a thermoplastic copolyesterelastomer is structurally different from a second thermoplasticcomposition comprising a thermoplastic styrene copolymer elastomer, orcomprising a thermoplastic polyurethane elastomer, based on the firstand second thermoplastic compositions comprising thermoplasticelastomers having different chemical structures In another example, afirst thermoplastic composition comprising a first 50,000 Daltonthermoplastic copolyester elastomer is structurally different than asecond thermoplastic composition comprising a second 100,000 Daltonthermoplastic copolyester elastomer having the same chemical structureas the first 50,000 Dalton thermoplastic copolyester, based on thenumber average molecular weight. In another example, a secondthermoplastic composition comprising the second 100,000 Daltonthermoplastic copolyester elastomer having the same chemical structureas the first 50,000 Dalton thermoplastic copolyester and also comprisingthe first 50,000 Dalton thermoplastic copolyester would still bestructurally different from the first thermoplastic composition, due tothe presence of the 100,000 Dalton thermoplastic composition in thesecond thermoplastic composition. In yet another example, a firstthermoplastic elastomer comprising 5 weight percent of a first 50,000Dalton thermoplastic copolyester is structurally different than a secondthermoplastic elastomer comprising 95 weight percent of the first 50,000Dalton thermoplastic copolyester.

In some aspects, a second thermoplastic composition includes at least 90weight percent, or at least 95 weight percent, or at least 99 weightpercent of a thermoplastic copolyester as disclosed herein, based on thetotal weight of the second thermoplastic composition. In some instances,the polymeric component of the second thermoplastic composition consistsessentially of only one or more disclosed thermoplastic copolyester.

The second thermoplastic composition can be disposed on at least oneexterior surface of the foam component. For example, where the foamarticle is a midsole, the second thermoplastic composition can be on allor part of the ground-facing (bottom) surface of the midsole, or on allor part of a side surface of the midsole, or any combination thereof.

In certain aspects, the disclosed methods comprise forming the secondthermoplastic composition integrally with the first component. Forexample, the polymeric material for the first component, e.g., adisclosed first thermoplastic copolyester composition, and the secondthermoplastic composition can be added to a mold sequentially during aninjection molding process to provide a unitary component having a foamportion and a second portion comprising the second thermoplasticcomposition. In this aspect, a mold can be provided having a first moldportion having a mold surface. The second thermoplastic composition canbe added to the mold, so as to form a layer of second thermoplasticcomposition on at least a portion of the mold surface. The firstthermoplastic composition for the first component, e.g., a disclosedthermoplastic copolyester composition, can be injected into the moldcontaining the second thermoplastic composition, and foamed while incontact with the second thermoplastic composition. The resultantinjection-molded component is a unitary component, with the secondthermoplastic composition bonded to the foam component. Alternatively oradditionally, the second thermoplastic composition can be disposed ontothe exterior surface of the foam component during a compression moldingstep. For example, a foam component can be made such as by injectionmolding, and the foam component can thereafter be compression molded ina mold which includes the second thermoplastic composition, and thesecond thermoplastic composition bonds to the surface of the foam duringthe compression molding process.

The second thermoplastic composition can be provided as a discrete layeror film to the injection mold or compression mold. For example, thelayer or film forming the second thermoplastic composition can beinserted into an injection mold and held in place against a targetsurface of the mold via vacuum ports, electrostatic charge or othermethod. The layer or film may be conformed to the target surface of themold, for example, with the application of heat or vacuum before orafter it is inserted into the mold. The first thermoplastic compositioncan then be injected into the mold containing the film, and foamed asdescribed herein. As a result the second thermoplastic composition ofthe layer or film becomes an integral part of the molded component.

Alternatively or additionally, the second thermoplastic composition canbe disposed onto the foam component after the foam component has beenformed. According to some of the disclosed methods, the secondthermoplastic composition is provided as a layer or film that isprovided separately from the foam component, and are thereafter operablycoupled so that the second thermoplastic composition forms a layer onthe targeted portion of the exterior surface of the foam. The secondthermoplastic composition may be coupled with the exterior surface of afoam component or article using any suitable method. In an aspect, thesecond thermoplastic composition may be adhesively laminated to the foamcomponent. In another aspect, the second thermoplastic composition maybe coupled with the foam component such as by thermally laminating to anexterior surface of the foam. For example, heat may be applied to anexterior surface of the foam component, to a surface of the secondthermoplastic composition, or both, to soften or melt the respectiveheated surface(s), and the two surfaces may be joined when one or bothare in the softened or melted state. In an aspect, the secondthermoplastic composition may be coupled with the foam component using aflame lamination process.

The second thermoplastic composition can be provided as a polymericcoating. For example, a polymeric coating can be formed by applying aliquid polymeric material onto the foam component, such as by spraying,dip coating, tumble-coating, brushing, or a combination thereof. Theliquid second thermoplastic composition can then be dried or cured whilein contact with the midsole.

The polymeric coating can be formed by applying a powdered secondthermoplastic composition onto the foam component, such as by spraying,powder-coating, electrostatically coating, tumble-coating, or acombination thereof. In some aspects, an adhesive could be used to affixthe powder to the midsole, and/or a coating can be applied over thepowder to hold it in place on the foam component. Once the powder isaffixed to the midsole, it can be left in the form of a powder, or itcan be treated so as to form a more uniform coating, such as by heatingit to melt it, by applying a solvent to solubilize it, etc.

Alternatively, the second thermoplastic composition can take the form ofa separate element which is applied to all or a portion of an exteriorsurface of the foam component when incorporating the midsole into anarticle of footwear. For example, the foam component can be a midsolecomponent of an article of footwear, and the second thermoplasticcomposition can be a rand or foxing tape applied around a perimeter ofthe midsole. The second thermoplastic composition can be an extension ofan outsole covering all or a portion of the bottom surface of themidsole, and which wraps up and covers at least a portion of thesidewall of the midsole. The second thermoplastic composition can be the“shell” portion of a core-shell sole structure, which covers both thebottom surface and the sidewalls of the midsole, and which is attachedto the upper of the article of footwear.

The resulting article comprising the first component with the secondthermoplastic composition can be characterized by good bonding strengthbetween the second thermoplastic composition and the foam component. Theply adhesion strength between the second thermoplastic composition andthe foam component is greater than 2.5 kg force/centimeter or greaterthan 3.0 kg force/centimeter, when determined using the Ply AdhesionTest method described herein.

Second Thermoplastic Composition Properties

The disclosed second thermoplastic composition can be characterized byone or more properties.

In one aspect, the polymeric layer composed of the second thermoplasticcomposition forms a water-resistant barrier on the at least a portion ofthe exterior surface of the first foam component. Here, the secondthermoplastic composition of the polymeric layer reduces or preventswater uptake by the open cell foam microstructure of first foamcomponent.

In one aspect, the foams and articles described herein having thepolymeric layer exhibit a beneficial Water Uptake Capacity. In otherwords, the foam articles having a polymeric layer as disclosed herein donot uptake either any water or a significant amount of water during theuse of the article. For example, the foam articles or foam componentshaving the polymeric layer have a Water Uptake Capacity at 2 hours ofless than 5 percent, or less than 4 percent, or less than 3 percent, orless than 2 percent, when determined using the Water Uptake CapacityTest method described herein. In comparison, an equivalent foam articleor foam component that lacks the polymeric layer may have a water uptakecapacity at 2 hours of greater than 2 percent, or from about 2 percentto about 30 percent, or from about 3 percent to about 25 percent or fromabout 5 percent to about 20 percent, when determined using the WaterUptake Capacity Test method described herein. The disclosed foamcomponent or article having the disclosed polymeric layer can have areduced water uptake when compared to an equivalent foam component orarticle that lacks the polymeric layer. For example, the disclosed foamcomponent or article can have a water uptake capacity at 2 hours that isabout 20 percent less, or about 30 percent less, or about 50 percentless than a water uptake capacity at 5 minutes for an equivalent foamcomponent or article that lacks the polymeric layer, when determinedusing the Water Uptake Capacity Test method describe herein. Thedisclosed foam component or article can have a water uptake capacity at5 minutes that is at least 2 percentage points less, or at least 3percentage points less, or at least 4 percentage points less, or atleast 5 percent less, or at least 6 percentage points less, or at least7 percentage points less, or at least 8 percentage points less, or atleast 9 percentage points less, or at least 10 percentage points less,or at least 11 percentage points less, or at least 12 percentage pointsless, or at least 13 percentage points less, or at least 14 percentagepoints less, or at least 15 percentage points less, or at least 20percentage points less, or at least 25 percentage points less, or atleast 30 percentage points less than a water uptake capacity at 5minutes for an equivalent foam component or article that lacks thepolymeric layer, when determined using the Water Uptake Capacity Testmethod describe herein

In some aspects, the second thermoplastic composition or the secondthermoplastic elastomer has a maximum load of about 10 newtons to about100 newtons, or from about 15 newtons to about 50 newtons, or from about20 newtons to about 40 newtons; or any load value or set of load valueswithin any of the foregoing ranges of load value, or any range of loadvalues encompassing a sub-set of any of the foregoing ranges, whendetermined using the Cyclic Tensile Test method described herein.

The tensile strength of the second thermoplastic composition or secondthermoplastic elastomer is another important physical characteristic.The second thermoplastic composition or resin can have a tensilestrength of from 5 kilograms per square centimeter to 25 kilograms persquare centimeter, or of from 10 kilograms per square centimeter to 23kilograms per square centimeter, or of from 15 kilograms per squarecentimeter to 22 kilograms per square centimeter; or any load value orset of load values within any of the foregoing ranges of load value, orany range of load values encompassing a sub-set of any of the foregoingranges, when determined using the Cyclic Tensile Test method describedherein.

The second thermoplastic composition or second thermoplastic elastomercan have a tensile modulus of about 2 megapascals to about 20megapascals or from about 5 megapascals to about 15 megapascals whendetermined using the Cyclic Tensile Test method described herein; or anyload value or set of load values within any of the foregoing ranges ofload value, or any range of load values encompassing a sub-set of any ofthe foregoing ranges.

The second thermoplastic composition can have an Akron abrasion of lessthan 0.50 cubic centimeters lost, optionally less than 0.40 cubiccentimeters lost, less than 0.30 cubic centimeters lost, less than 0.20cubic centimeters lost, or less than 0.10 cubic centimeters lost asdetermined using the Akron Abrasion Test. The second thermoplasticcomposition can have an Akron abrasion of about 0.05 cubic centimeterslost, about 0.10 cubic centimeters lost, about 0.15 cubic centimeterslost, about 0.20 cubic centimeters lost, about 0.25 cubic centimeterslost, about 0.30 cubic centimeters lost, about 0.35 cubic centimeterslost, about 0.40 cubic centimeters lost, about 0.45 cubic centimeterslost, or about 0.50 cubic centimeters lost as determined using the AkronAbrasion Test, any range of abrasion values encompassed by any of theforegoing values, or any combination of the foregoing abrasion values.

The second thermoplastic composition can have an Akron abrasion of lessthan 500 milligrams lost, optionally less than 400 milligrams lost, lessthan 300 milligrams lost, less than 200 milligrams lost, or less than100 milligrams lost as determined using the Akron Abrasion Test. Thesecond thermoplastic composition can have an Akron abrasion of about 50milligrams lost, about 100 milligrams lost, about 150 milligrams lost,about 200 milligrams lost, about 250 milligrams lost, about 300milligrams lost, about 350 milligrams lost, about 400 milligrams lost,about 450 milligrams lost, or about 500 milligrams lost as determinedusing the Akron Abrasion Test, any range of abrasion values encompassedby any of the foregoing values, or any combination of the foregoingabrasion values.

The second thermoplastic composition can have a DIN abrasion of lessthan 0.30 cubic centimeters lost, optionally less than 0.20 cubiccentimeters lost, less than 0.10 cubic centimeters lost, less than 0.05cubic centimeters lost, or less than 0.03 cubic centimeters lost asdetermined using the DIN Abrasion Test. The second thermoplasticcomposition can have a DIN abrasion of about 0.01 cubic centimeterslost, about 0.05 cubic centimeters lost, about 0.10 cubic centimeterslost, about 0.15 cubic centimeters lost, about 0.20 cubic centimeterslost, about 0.25 cubic centimeters lost, or about 0.30 cubic centimeterslost as determined using the DIN Abrasion Test, any range of abrasionvalues encompassed by any of the foregoing values, or any combination ofthe foregoing abrasion values.

The second thermoplastic composition can have a DIN abrasion of lessthan 300 milligrams lost, optionally less than 250 milligrams lost,optionally less than 200 milligrams lost, optionally less than 150milligrams lost, optionally less than 100 milligrams lost, optionallyless than 80 milligrams lost, optionally less than 50 milligrams lost,or optionally less than 30 milligrams as determined using the DINAbrasion Test. The second thermoplastic composition can have a DINabrasion of about 10 milligrams lost, about 50 milligrams lost, about100 milligrams lost, about 150 milligrams lost, about 200 milligramslost, about 250 milligrams lost, or about 300 milligrams lost asdetermined using the DIN Abrasion Test, any range of abrasion valuesencompassed by any of the foregoing values, or any combination of theforegoing abrasion values.

The second thermoplastic composition described herein when incorporatedinto an article the product has improved traction properties. In oneaspect, the coefficient of friction of the second thermoplasticcomposition can be used to measure traction properties.

The second thermoplastic composition can have a dry dynamic coefficientof friction (COF) on a dry surface (e.g., a smooth, flat, or texturedsurface such as, for example, wooden parquet court, concrete, asphalt,laminate, brick, or ceramic tile) of greater than 0.5, optionally ofgreater than 0.7, greater than 0.8, greater than 0.9, greater than 1.0,as determined using the Dry Outsole Coefficient of Friction Test. Thesecond thermoplastic composition can have a dry dynamic COF of greaterthan 0.15, optionally of greater than 0.2, greater than 0.25, or greaterthan 0.3, using the Dry Upper Coefficient of Friction Test.

The second thermoplastic composition can have a wet dynamic COF ofgreater than 0.25, optionally of greater than 0.30, greater than 0.35,greater than 0.40, or greater than 0.50, as determined using the WetOutsole Coefficient of Friction Test. The second thermoplasticcomposition can have a wet dynamic COF of greater than 0.15, optionallyof greater than 0.2, greater than 0.25, or greater than 0.3, using theWet Upper Coefficient of Friction Test.

It may be desirable for the dynamic coefficient of friction for the samedry and wet surface (e.g., smooth concrete or court) to be as close aspossible. In one aspect, the difference between the dynamic coefficientof friction of the dry surface and the wet surface is less than 15percent. In another aspect, the difference between the dynamiccoefficient of friction of the dry surface and the wet surface is about0 percent, about 1 percent, about 2 percent, about 3 percent, about 4percent, about 5 percent, about 6 percent, about 7 percent, about 8percent, about 9 percent, about 10 percent, about 11 percent, about 12percent, about 13 percent, about 14 percent, or about 15 percent, anyrange of percentage values encompassed by any of the foregoing values,or any combination of the foregoing percentage values.

The second thermoplastic composition can have a melting temperature fromabout 100 degrees centigrade to about 210 degrees centigrade, optionallyfrom about 110 degrees centigrade to about 195 degrees centigrade, fromabout 120 degrees centigrade to about 180 degrees centigrade, or fromabout 120 degrees centigrade to about 170 degrees centigrade. Themelting temperature of the second thermoplastic composition can bewithin about 50 degrees centigrade, or about 40 degrees centigrade, orabout 30 degrees centigrade, or about 20 degrees centigrade of the firstthermoplastic composition.

The second thermoplastic composition can have a melt flow rate of atleast 0.2 grams per 10 minutes, optionally at least 5, at least 10, atleast 15, at least 20, at least 25, at least 30, at least 40, or atleast 50 grams per 10 minutes, as determined using ASTM D1238-13 at 160degrees centigrade using a weight of 2.16 kg. The second thermoplasticcomposition can have a melt flow rate of at least 0.2 grams per 10minutes, optionally at least 5, at least 10, at least 15, at least 20,at least 25, at least 30, at least 40, or at least 50 grams per 10minutes, as determined using ASTM D1238-13 at 200 degrees centigradeusing a weight of 10 kg.

The second thermoplastic composition can have a melting temperature fromabout 100 degrees centigrade to about 210 degrees centigrade, optionallyfrom about 110 degrees centigrade to about 195 degrees centigrade, fromabout 120 degrees centigrade to about 180 degrees centigrade, or fromabout 120 degrees centigrade to about 170 degrees centigrade.

The second thermoplastic composition can have a melt flow index of fromabout 5 to about 40, or about 10 to about 20, or about 20 to about 30 asdetermined at 210 degrees centigrade using a 2.16 kilogram weight.Alternatively or additionally, the second thermoplastic composition canhave a melt flow index of from about 5 to about 40, or about 10 about20, or about 20 to about 30 as determined at 220 degrees centigradeusing a 2.16 kilogram weight. Alternatively or additionally, the secondthermoplastic composition can have a melt flow index of from about 5 toabout 40, or about 10 to about 20, or about 20 to about 30 as determinedat 230 degrees centigrade using a 2.16 kilogram weight.

The second thermoplastic composition can have a durometer Shore Ahardness of less than 90 or less than 85 or less than 80. The secondthermoplastic composition can have a durometer Shore A hardness ofgreater than 60 or greater than 65. The second thermoplastic compositioncan have a durometer Shore A hardness of about 50 to about 90 Shore A,optionally from about 55 to about 85 Shore A, from about 60 to about 80Shore A, or from about 60 to about 70 Shore A.

In the foamed article, the second thermoplastic composition can have aspecific gravity from about 0.8 to about 1.5, optionally from about 0.85to about 1.30, or from about 0.88 to about 1.20. Alternatively, in thefoamed article, the second thermoplastic composition can be amulticellular foam having a specific gravity of from about 0.15 to about0.60, or from about 0.15 to about 0.40, or from about 0.15 to about0.25.

The second thermoplastic composition can have two or more of the firstproperties, or optionally three or more, four or more, five or more, sixor more, seven or more, or all ten first properties provided above.

In addition to the first properties, the second thermoplasticcomposition can have one or more second properties. The secondthermoplastic composition can have a glass transition temperature lessthan 50 degrees centigrade, optionally less than 30 degrees centigrade,less than 0 degrees centigrade, less than −10 degrees centigrade, orless than −20 degrees centigrade. The second thermoplastic compositioncan have a stress at break greater than 7 megapascals, optionallygreater than 8 megapascals, or greater than 8 megapascals as determinedusing ASTM DE-412 at 25 degrees centigrade The second thermoplasticcomposition can have a tensile stress at 300 percent modulus greaterthan 2 megapascals, optionally greater than 2.5 megapascals, or greaterthan 3 megapascals as determined using ASTM DE-412 at 25 degreescentigrade The second thermoplastic composition can have an elongationat break greater than 450 percent, optionally greater than 500 percent,or greater than 550 percent as determined using ASTM DE-412 at 25degrees centigrade. The second thermoplastic composition can have two ormore of the second properties, or optionally three or more, or all foursecond properties.

According to the various aspects, the disclosed foam article has apolymeric layer disposed on at least one exterior surface of the foamcomponent. For example, the polymeric layer can be a polymeric coatingor a polymeric film. In some aspects, the polymeric layer acts as afluid barrier that controls or prevents water uptake by the foamarticle. The polymeric layer may be integral with the foam component, ormay be a separate component that is operably coupled with the foamcomponent, as described herein.

The polymeric layer can be disposed on at least one exterior surface ofthe foam component. For example, where the foam article is a midsole,the coating can be on all or part of the sidewall of the midsole, or onall or part of a ground-facing (bottom) surface of the midsole, or onall or part of an upper-facing (top) surface of the midsole, or anycombination thereof. The polymeric layer can be disposed on at least onesurface that may be exposed to moisture during normal use of thefinished article, e.g., an article of footwear.

As disposed on the foam component, the polymeric layer has an averagethickness of about 0.01 millimeter to about 3 millimeter, or about 0.03millimeter to about 2 millimeter, or from about 0.1 millimeter to about1 millimeter.

Thermoplastic Elastomers

The first and second thermoplastic compositions described herein cancomprise one or more thermoplastic elastomers. Exemplary thermoplasticelastomers include thermoplastic homo-polymer elastomer andthermoplastic co-polymer elastomers. The thermoplastic elastomer can bea thermoplastic random co-polymer elastomer. The thermoplastic elastomercan be a thermoplastic block co-polymer elastomer. The term “polymer”refers to a polymerized molecule having one or more monomer species, andincludes homopolymers and copolymers. The term “copolymer” refers to apolymer having two or more monomer species, and includes terpolymers(i.e., copolymers having three monomer species). For example, thethermoplastic elastomer can be a block co-polymer having repeatingblocks of polymeric units of the same chemical structure (segments)which are relatively harder (hard segments), and repeating blocks ofpolymeric segments which are relatively softer (soft segments). Invarious aspects, in block co-polymers, including block co-polymershaving repeating hard segments and soft segments, physical crosslinkscan be present within the blocks or between the blocks or both withinand between the blocks. Particular examples of hard segments includeisocyanate segments and polyamide segments. Particular examples of softsegments include polyether segments and polyester segments. As usedherein, the polymeric segment can be referred to as being a particulartype of polymeric segment such as, for example, an isocyanate segment, apolyamide segment, a polyether segment, a polyester segment, and thelike. It is understood that the chemical structure of the segment isderived from the described chemical structure. For example, anisocyanate segment is a polymerized unit including an isocyanatefunctional group. When referring to a block of polymeric segments of aparticular chemical structure, the block can contain up to 10 molpercent of segments of other chemical structures. For example, as usedherein, a polyether segment is understood to include up to 10 molpercent of non-polyether segments.

The thermoplastic elastomer can include one or more of a thermoplasticpolyester elastomer, a thermoplastic polyurea elastomer, a thermoplasticpolyimide elastomer, a thermoplastic polyamide elastomer, athermoplastic polyether elastomer, a thermoplastic polyurethaneelastomer, a thermoplastic polyolefin elastomer, a thermoplastic ionomerelastomer, any copolymer thereof, or any blend thereof. It should beunderstood that other thermoplastic polymeric materials not specificallydescribed below are also contemplated for use in the coated fiber asdescribed herein and/or the uncoated fiber.

The second thermoplastic composition can include one or more ofthermoplastic polyamide elastomers, such as PEBA or polyether blockpolyamides. The second thermoplastic composition can comprise one ormore metallocene-catalyzed block copolymers of ethylene and α-olefinshaving 4 to about 8 carbon atoms. The second thermoplastic compositioncan comprise one or more thermoplastic styrene copolymers, includingstyrene block copolymers such as poly(styrene-butadiene-styrene),poly(styrene-ethylene-co-butylene-styrene), andpoly(styrene-isoprene-styrene), and combinations thereof.

The second thermoplastic composition can include at least onethermoplastic polyester, including at least one thermoplasticcopolyester. Exemplary, but non-limiting, thermoplastic copolyesterelastomers, including thermoplastic copolyesters, that can be used inthe disclosed methods, foams, and articles include “HYTREL” 3078,“HYTREL” 4068, and “HYTREL” 4556 (DuPont, Wilmington, Del., USA);“PELPRENE” P30B, P40B, and P40H (Toyobo U.S.A. Inc., New York, N.Y.,USA); “TRIEL” 5300, “TRIEL” 5400, and blends thereof (SamyangCorporation, Korea); “KEYFLEX” BT1028D, BT1033D, BT1035D, BT1040D,BT1045D, and BT1047D (LG Chem, Korea); and “KOPEL” KP3340, KP3346,KP3347, KP3942 (Kolon Plastics, Inc., Korea). The polymeric component ofsecond thermoplastic composition (i.e., the component consisting of allthe polymers present in the second polymeric material) can comprise atleast 80 weight percent of thermoplastic copolyester elastomers, or atleast 90 weight percent of thermoplastic copolyester elastomers, or atleast 95 weight percent of thermoplastic copolyester elastomers, basedon a total weight of the second thermoplastic composition.

The second thermoplastic composition can include one or morethermoplastic polyurethanes (TPUs), such as “FORTIMO” (Mitsui Chemicals,Inc., Tokyo, Japan); “TEXIN” (Covestro LLC, Pittsburgh, Pa., USA); and“BOUNCELL-X” (Lubrizol Advanced Materials, Inc., Brecksville, Ohio,USA). The polymeric component of second thermoplastic composition (i.e.,the component consisting of all the polymers present in the secondthermoplastic composition) can comprise at least 80 weight percent ofTPU elastomers, or at least 90 weight percent of TPU elastomers, or atleast 95 weight percent of TPU elastomers, based on a total weight ofthe second thermoplastic composition. The second thermoplasticcomposition can include one or more thermoplastic polyurethane hot-meltadhesives, such as, for example, “NASA-T” hot-melt film (Sambu FineChemicals, Gimhae-si, Gyeongsangdam-do, Korea).

The second thermoplastic composition can comprise a blend of one or morethermoplastic polyurethane elastomers with one or more thermoplasticpolymers having a different chemical structure. In one aspect, thesecond thermoplastic composition comprises one or more thermoplasticpolyurethane elastomers and one or more ethylene-vinyl alcoholcopolymers. In another aspect, the second thermoplastic compositioncomprises one or more thermoplastic elastomers and one or morethermoplastic polystyrene elastomers, such as, for example, one or moreSEBS copolymer elastomers.

The thermoplastic composition can include one or more olefinic polymers.Olefinic polymers can include ethylene-based copolymers, propylene-basedcopolymers, and butene-based copolymers. The olefinic polymer can be anethylene-based copolymer such as a styrene-ethylene/butylene-styrene(SEBS) copolymer; an ethylene-propylene diene monomer (EPDM) copolymer;an ethylene-vinyl acetate (EVA) copolymer; an ethylene-vinyl alcohol(EVOH) copolymer; an ethylene alkyl acrylate (EAA) copolymer; anethylene alkyl methacrylate (EAMA) copolymer; any copolymer thereof, andany blend thereof.

The thermoplastic composition can include one or more olefinic polymers.Olefinic polymers can include ethylene-based copolymers, propylene-basedcopolymers, and butene-based copolymers. In some aspects, the olefinicpolymer is an ethylene-based copolymer such as astyrene-ethylene/butylene-styrene (SEBS) copolymer; anethylene-propylene diene monomer (EPDM) copolymer; an ethylene-vinylacetate (EVA) copolymer; an ethylene alkyl acrylate (EAA) copolymer; anethylene alkyl methacrylate (EAMA) copolymer; any copolymer thereof, andany blend thereof. In some aspects, a ratio of a total parts by weightof the olefinic polymers present in the composition to a total parts byweight of the thermoplastic copolyesters or of the second thermoplasticcomposition in the composition is about 0.0 to about 0.6, about 0.0 toabout 0.4, about 0.01 to about 0.4, or about 0.01 to about 0.6, or about0.1 to about 0.4.

The thermoplastic composition can include an ethylene-vinyl acetate(EVA) copolymer. The ethylene-vinyl acetate (EVA) copolymer can have arange of vinyl acetate contents, for example about 50 percent to about90 percent, about 50 percent to about 80 percent, about 5 percent toabout 50 percent, about 10 percent to about 45 percent, about 10 percentto about 30 percent, about 30 percent to about 45 percent, or about 20percent to about 35 percent.

The second thermoplastic composition can include one or more ionomers,such as any of the “SURLYN” polymers (DuPont, Wilmington, Del., USA).

The thermoplastic elastomer can have a melting temperature greater thanabout 110 degrees centigrade and less than about 210 degrees centigradeor less than about 170 degrees centigrade.

The thermoplastic elastomer can have a glass transition temperature lessthan 50 degrees centigrade, or less than 20 degrees centigrade, or lessthan 0 degrees centigrade, or less than −10 degrees centigrade, whendetermined in accordance with ASTM D3418-97 as described herein below.

Thermoplastic Polyurethane Elastomers

The thermoplastic elastomer can be a thermoplastic polyurethaneelastomer. The thermoplastic polyurethane elastomer can be athermoplastic block polyurethane co-polymer. The thermoplastic blockpolyurethane co-polymer can be a block copolymer having blocks of hardsegments and blocks of soft segments. The hard segments can comprise orconsist of isocyanate segments. The soft segments can comprise orconsist of polyether segments, or polyester segments, or a combinationof polyether segments and polyester segments. The thermoplastic materialcan comprise or consist essentially of an elastomeric thermoplasticpolyurethane having repeating blocks of hard segments and repeatingblocks of soft segments.

One or more of the thermoplastic polyurethane elastomer can be producedby polymerizing one or more isocyanates with one or more polyols toproduce copolymer chains having carbamate linkages (—N(CO)O—) asillustrated below in Formula 7 below,

where the isocyanate(s) each preferably include two or more isocyanate(—NCO) groups per molecule, such as 2, 3, or 4 isocyanate groups permolecule (although, single-functional isocyanates can also be optionallyincluded, e.g., as chain terminating units). In these aspects, each R₁and R₂ independently is an aliphatic or aromatic segment. Optionally,each R₂ can be a hydrophilic segment.

Unless otherwise indicated, any of the functional groups or chemicalcompounds described herein can be substituted or unsubstituted. A“substituted” group or chemical compound, such as an alkyl, alkenyl,alkynyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxyl, ester,ether, or carboxylic ester refers to an alkyl, alkenyl, alkynyl,cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxyl, ester, ether, orcarboxylic ester group, has at least one hydrogen radical that issubstituted with a non-hydrogen radical (i.e., a substituent). Examplesof non-hydrogen radicals (or substituents) include, but are not limitedto, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, ether, aryl,heteroaryl, heterocycloalkyl, hydroxyl, oxy (or oxo), alkoxyl, ester,thioester, acyl, carboxyl, cyano, nitro, amino, amido, sulfur, and halo.When a substituted alkyl group includes more than one non-hydrogenradical, the substituents can be bound to the same carbon or two or moredifferent carbon atoms.

Additionally, the isocyanates can also be chain extended with one ormore chain extenders to bridge two or more isocyanates. This can producepolyurethane copolymer chains as illustrated below in Formula 8,

wherein R₃ includes the chain extender. As with each R₁ and R₃, each R₃independently is an aliphatic or aromatic segment.

Each segment R₁, or the first segment, in Formulas 7 and 8 canindependently include a linear or branched C₃₋₃₀ segment, based on theparticular isocyanate(s) used, and can be aliphatic, aromatic, orinclude a combination of aliphatic portions(s) and aromatic portion(s).The term “aliphatic” refers to a saturated or unsaturated organicmolecule that does not include a cyclically conjugated ring systemhaving delocalized pi electrons. In comparison, the term “aromatic”refers to a cyclically conjugated ring system having delocalized pielectrons, which exhibits greater stability than a hypothetical ringsystem having localized pi electrons.

Each segment R₁ can be present in an amount of 5 percent to 85 percentby weight, from 5 percent to 70 percent by weight, or from 10 percent to50 percent by weight, based on the total weight of the reactantmonomers.

In aliphatic aspects (from aliphatic isocyanate(s)), each segment R₁ caninclude a linear aliphatic group, a branched aliphatic group, acycloaliphatic group, or combinations thereof. For instance, eachsegment R₁ can include a linear or branched C₃₋₂₀ alkylene segment(e.g., C₄₋₁₅ alkylene or C₆₋₁₀ alkylene), one or more C₃₋₈cycloalkylenesegments (e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl,cycloheptyl, or cyclooctyl), and combinations thereof.

Examples of suitable aliphatic diisocyanates for producing thepolyurethane copolymer chains include hexamethylene diisocyanate (HDI),isophorone diisocyanate (IPDI), butylenediisocyanate (BDI),bisisocyanatocyclohexylmethane (HMDI), 2,2,4-trimethylhexamethylenediisocyanate (TMDI), bisisocyanatomethylcyclohexane,bisisocyanatomethyltricyclodecane, norbornane diisocyanate (NDI),cyclohexane diisocyanate (CHDI), 4,4′-dicyclohexylmethane diisocyanate(H12MDI), diisocyanatododecane, lysine diisocyanate, and combinationsthereof.

In aromatic aspects (from aromatic isocyanate(s)), each segment R₁ caninclude one or more aromatic groups, such as phenyl, naphthyl,tetrahydronaphthyl, phenanthrenyl, biphenylenyl, indanyl, indenyl,anthracenyl, and fluorenyl. Unless otherwise indicated, an aromaticgroup can be an unsubstituted aromatic group or a substituted aromaticgroup, and can also include heteroaromatic groups. “Heteroaromatic”refers to monocyclic or polycyclic (e.g., fused bicyclic and fusedtricyclic) aromatic ring systems, where one to four ring atoms areselected from oxygen, nitrogen, or sulfur, and the remaining ring atomsare carbon, and where the ring system is joined to the remainder of themolecule by any of the ring atoms. Examples of suitable heteroarylgroups include pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl,imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isooxazolyl, thiadiazolyl,oxadiazolyl, furanyl, quinolinyl, isoquinolinyl, benzoxazolyl,benzimidazolyl, and benzothiazolyl.

Examples of suitable aromatic diisocyanates for producing thepolyurethane copolymer chains include toluene diisocyanate (TDI), TDIadducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate(MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate(TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate,para-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI),4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In someaspects, the copolymer chains are substantially free of aromatic groups.

The polyurethane copolymer chains can be produced from diisocyanatesincluding HMDI, TDI, MDI, H₁₂ aliphatics, and combinations thereof. Forexample, the coated fiber as described herein of the present disclosurecan comprise one or more polyurethane copolymer chains are produced fromdiisocynates including HMDI, TDI, MDI, H₁₂ aliphatics, and combinationsthereof.

Commercially available thermoplastic polyurethane elastomers havinggreater hydrophilicity suitable for the present use include, but are notlimited to those under the tradename “TECOPHILIC”, such as TG-500,TG-2000, SP-80A-150, SP-93A-100, SP-60D-60 (Lubrizol, Countryside,Ill.), “ESTANE” (e.g., 58238, T470A-, 2350-75A-030; Lubrizol,Countryside, Ill.), and “ELASTOLLAN” (e.g., 9500, B70A; BASF).

The thermoplastic polyurethane elastomer can be partially covalentlycrosslinked, as previously described herein.

The second thermoplastic composition can include one or morethermoplastic polyurethanes (TPUs), such as “FORTIMO” (Mitsui Chemicals,Inc., Tokyo, Japan); “TEXIN” (Covestro LLC, Pittsburgh, Pa., USA); and“BOUNCELL-X” (Lubrizol Advanced Materials, Inc., Brecksville, Ohio,USA). The polymer component of second thermoplastic composition (i.e.,the component consisting of all the polymers present in the secondthermoplastic composition) can comprise at least 80 weight percent ofTPUs, or at least 90 weight percent of TPUs, or at least 95 weightpercent of TPUs, based on a total weight of the second thermoplasticcomposition. The second thermoplastic composition can include one ormore thermoplastic polyurethane hot-melt adhesives, such as, forexample, “NASA-T” hot-melt film (Sambu Fine Chemicals, Gimhae-si,Gyeongsangdam-do, Korea).

Thermoplastic Block Co-Polyamide Elastomers

In various aspects, the second thermoplastic composition as describedherein can comprise one or more thermoplastic elastomers comprising athermoplastic block co-polyamide elastomer. The thermoplastic blockco-polyamide can comprise a number of polyamide segments havingdifferent polyamide chemical structures (e.g., polyamide 6 segments,polyamide 11 segments, polyamide 12 segments, polyamide 66 segments,etc.). The polyamide segments having different chemical structure can bearranged randomly, or can be arranged as repeating blocks.

The block co-polyamide can have repeating blocks of hard segments, andrepeating blocks soft segments. The hard segments can comprise polyamidesegments, and the soft segments can comprise non-polyamide segments. Thethermoplastic elastomer can be an elastomeric thermoplastic co-polyamidecomprising or consisting of block co-polyamides having repeating blocksof hard segments and repeating blocks of soft segments. In blockco-polymers, including block co-polymers having repeating hard segmentsand soft segments, physical crosslinks can be present within the blocksor between the blocks or both within and between the blocks.

The polyamide segments of the block co-polyamide can comprise or consistof polyamide 6 segments, polyamide 11 segments, polyamide 12 segments,polyamide 66 segments, or any combination thereof. The polyamidesegments of the co-polyamide can be arranged randomly, or can bearranged as repeating blocks. In a particular example, the polyamidesegments can comprise or consist of polyamide 6 segments, or polyamide12 segments, or both polyamide 6 segment and polyamide 12 segments. Inthe example where the polyamide segments of the co-polyamide include ofpolyamide 6 segments and polyamide 12 segments, the segments can bearranged randomly. The non-polyamide segments of the co-polyamide cancomprise or consist of polyether segments, polyester segments, or bothpolyether segments and polyester segments. The co-polyamide can be ablock co-polyamide, or can be a random co-polyamide. The thermoplasticcopolyamide can be formed from the polycodensation of a polyamideoligomer or prepolymer with a second oligomer prepolymer to form a blockcopolyamide (i.e., a block co-polymer including polyamide segments.Optionally, the second prepolymer can be a hydrophilic prepolymer.

Exemplary commercially available copolymers include, but are not limitedto, those available under the tradenames of VESTAMID® (EvonikIndustries); PELATAMID® (Arkema), e.g., product code H2694; PEBAX®(Arkema), e.g., product code “PEBAX MH1657” and “PEBAX MV1074”; PEBAX®RNEW (Arkema); GRILAMID® (EMS-Chemie AG), or also to other similarmaterials produced by various other suppliers.

Thermoplastic Polyolefin Elastomers

In some aspects, the thermoplastic elastomers can comprise or consistessentially of a thermoplastic polyolefin. Exemplary of thermoplasticpolyolefins useful in the disclosed second thermoplastic compositionscan include, but are not limited to, thermoplastic olefin elastomers(e.g., metallocene-catalyzed block copolymers of ethylene and α-olefinshaving 4 to about 8 carbon atoms). The thermoplastic polyolefin can be apolymer comprising an ethylene-α-olefin copolymer, an ethylene-propylenerubber (EPDM), a polybutene, a polyisobutylene, apoly-4-methylpent-1-ene, a polyisoprene, a polybutadiene, anethylene-methacrylic acid copolymer, and an olefin elastomer such as adynamically cross-linked polymer obtained from polypropylene (PP) and anethylene-propylene rubber (EPDM), and blends or mixtures of theforegoing. Further exemplary thermoplastic polyolefins useful in thedisclosed second thermoplastic compositions are polymers of cycloolefinssuch as cyclopentene or norbornene.

The polyolefin can be a polyethylene copolymer derived from monomers ofmonolefins and diolefins copolymerized with a vinyl, acrylic acid,methacrylic acid, ethyl acrylate, vinyl alcohol, and/or vinyl acetate.Polyolefin copolymers comprising vinyl acetate-derived units can be ahigh vinyl acetate content copolymer, e.g., greater than about 50 wtpercent vinyl acetate-derived composition.

The thermoplastic polyolefin can be a mixture of thermoplasticpolyolefins, such as a mixture of two or more polyolefins disclosedherein above. For example, a suitable mixture of thermoplasticpolyolefins can be a mixture of polypropylene with polyisobutylene,polypropylene with polyethylene (for example PP/HDPE, PP/LDPE) ormixtures of different types of polyethylene (for example LDPE/HDPE).

The thermoplastic polyolefin can be a copolymer of suitable monolefinmonomers or a copolymer of a suitable monolefin monomer and a vinylmonomer. Exemplary thermoplastic polyolefin copolymers include, but arenot limited to, ethylene/propylene copolymers, linear low densitypolyethylene (LLDPE) and mixtures thereof with low density polyethylene(LDPE), propylene/but-1-ene copolymers, propylene/isobutylenecopolymers, ethylene/but-1-ene copolymers, ethylene/hexene copolymers,ethylene/methylpentene copolymers, ethylene/heptene copolymers,ethylene/octene copolymers, propylene/butadiene copolymers,isobutylene/isoprene copolymers, ethylene/alkyl acrylate copolymers,ethylene/alkyl methacrylate copolymers, ethylene/vinyl acetatecopolymers and their copolymers with carbon monoxide or ethylene/acrylicacid copolymers and their salts (ionomers) as well as terpolymers ofethylene with propylene and a diene such as hexadiene, dicyclopentadieneor ethylidene-norbornene; and mixtures of such copolymers with oneanother and with polymers mentioned in 1) above, for examplepolypropylene/ethylene-propylene copolymers, LDPE/ethylene-vinyl acetatecopolymers (EVA), LDPE/ethylene-acrylic acid copolymers (EAA),LLDPE/EVA, LLDPE/EAA and alternating or random polyalkylene/carbonmonoxide copolymers and mixtures thereof with other polymers, forexample polyamides.

The polyolefin can be a polypropylene. The term “polypropylene,” as usedherein, is intended to encompass any polymeric composition comprisingpropylene monomers, either alone or in mixture or copolymer with otherrandomly selected and oriented polyolefins, dienes, or other monomers(such as ethylene, butylene, and the like). Such a term also encompassesany different configuration and arrangement of the constituent monomers(such as atactic, syndiotactic, isotactic, and the like). Thus, the termas applied to fibers is intended to encompass actual long strands,tapes, threads, and the like, of drawn polymer. The polypropylene can beof any standard melt flow (by testing); however, standard fiber gradepolypropylene resins possess ranges of Melt Flow Indices between about 1and 1000.

The polyolefin can be a polyethylene. The term “polyethylene,” as usedherein, is intended to encompass any polymeric composition comprisingethylene monomers, either alone or in mixture or copolymer with otherrandomly selected and oriented polyolefins, dienes, or other monomers(such as propylene, butylene, and the like). Such a term alsoencompasses any different configuration and arrangement of theconstituent monomers (such as atactic, syndiotactic, isotactic, and thelike). Thus, the term as applied to fibers is intended to encompassactual long strands, tapes, threads, and the like, of drawn polymer. Thepolyethylene can be of any standard melt flow (by testing); however,standard fiber grade polyethylene resins possess ranges of Melt FlowIndices between about 1 and 1000.

Thermoplastic Ionomer Elastomers

In certain aspects, the thermoplastic elastomer can be one or moreionomeric polymers. The ionomeric polymers can include chain unitsderived from one or more olefins and chain units derived from one ormore ethylenically-unsaturated acid groups. The compositions can alsoinclude a plurality of cations ionically crosslink anionic form of theacid groups in the ionomeric copolymers. The compositions can beessentially just the ionomeric copolymers and metal cations. Theionomeric copolymers can have a melt flow index of about 30 or less,about 20 or less, about 15 or less, about 10 or less, or about 5 orless.

The ionomeric copolymers can be terpolymers of ethylene, acrylic acid,and methyl acrylate or butyl acrylate. In some aspects, a ratio III of atotal parts by weight of the acrylic acid in the ionomeric copolymers toa total weight of the ionomeric copolymers is about 0.05 to about 0.6,about 0.1 to about 0.6, about 0.1 to about 0.5, about 0.15 to about 0.5,or about 0.2 to about 0.5.

The second thermoplastic composition can include one or more ionomers,such as any of the “SURLYN” polymers (DuPont, Wilmington, Del., USA.

The second thermoplastic composition can include acrylic block copolymerelastomers, such as block copolymers comprising a first PMMA block, anacrylate block, and a second PMMA block.

Thermoplastic Styrenic Copolymer Elastomers

In certain aspects, the thermoplastic elastomer is a thermoplasticelastomeric styrenic copolymer. Examples of these copolymers include,but are not limited to, styrene butadiene styrene (SBS) block copolymer,a styrene ethylene/butylene styrene (SEBS) resin, a polyacetal resin(POM) or a styrene acrylonitrile resin (SAN). Exemplary commerciallyavailable thermoplastic elastomeric styrenic copolymers includeMONOPRENE IN5074, SP066070, and SP16975 (Teknor Apex), which are styreneethylene/butylene styrene (SEBS) resins.

Thermoplastic Vulcanizate Materials

The second thermoplastic composition can include an injectionprocessible thermoplastic vulcanizate (TPV) material.Injection-processible TPV materials are typically cross-linked orpartially cross-linked rubbers dispersed into thermoplastic host phases.Exemplary TPV materials include ethylene propylene diene rubber inpolypropylene hosts (EPDM/PP), such as “SARLINK” or “SANTOPRENE” TPVmaterials. Other exemplary TPV materials include alkyl acrylic copolymerrubbers in polyamide hosts (ACM/PA), such as “ZEOTHERM” TPVs. Yet otherexemplary TPV materials include silicone rubbers dispersed in “HYTREL”based copolyesters (e.g., so-called TSiPVs).

Additives

In various aspects, the disclosed first thermoplastic composition andsecond thermoplastic composition can independently further comprise anadditive. The additive can be incorporated directly into the disclosedfirst thermoplastic composition or second thermoplastic composition, oralternatively, applied thereto, prior to foaming the first thermoplasticcomposition or second thermoplastic composition. Additives that can beused in the disclosed compositions and materials include, but are notlimited to, dyes, pigments, colorants, ultraviolet light absorbers,hindered amine light stabilizers, antioxidants, processing aids oragents, plasticizers, lubricants, emulsifiers, pigments, dyes, opticalbrighteners, rheology additives, catalysts, flow-control agents, slipagents, crosslinking agents, crosslinking boosters, halogen scavengers,smoke inhibitors, flameproofing agents, antistatic agents, fillers, ormixtures of two or more of the foregoing. In some aspects, the additivecan be a wax, an anti-oxidant, a UV-absorbing agent, a coloring agent,or combinations thereof.

The additive can be present in an amount from about 0.1 weight percentto about 10 weight percent, or from 0.1 to 6 weight percent, based onthe total weight of the first or second thermoplastic composition. In aparticular aspect, the additive can be present in the first or secondthermoplastic composition in an amount from about 0.1 weight percent toabout 4 weight percent, based on a total weight of the first or secondthermoplastic composition. The first or second thermoplastic compositioncan comprise less than 4 weight percent, or less than 3 weight percent,or less than 2 weight percent, or less than 1 weight percent ofadditives, based on a total weight of the first or second thermoplasticcomposition.

The first and/or second thermoplastic composition can be essentiallyfree of additives, where the amount of additive is less than about 0.1weight percent, about 0.08 weight percent, about 0.06 weight percent,about 0.04 weight percent, or about 0.02 weight percent of the firstand/or second thermoplastic composition. In another aspect, the firstand/or second thermoplastic composition is free of any additives (i.e.,contains no additives).

In some instances, an additive can be present in an amount of from about0.01 weight percent to about 10 weight percent, about 0.025 weightpercent to about 5 weight percent, or about 0.1 weight percent to 3weight percent, where the weight percent is based upon the sum of thematerial components in the first thermoplastic composition or secondthermoplastic composition.

Individual components can be mixed together with the other components ofthe first thermoplastic composition or second thermoplastic compositionin a continuous mixer or a batch mixer, e.g., in an intermeshing rotormixer, such as an Intermix mixer, a twin screw extruder, in a tangentialrotor mixer such as a Banbury mixer, using a two-roll mill, or somecombinations of these to make a composition comprising a thermoplasticpolymer and an additive. The mixer can blend the components together viaa single step or multiple steps, and can mix the components viadispersive mixing or distributive mixing to form the resultingthermoplastic composition. This step is often referred to as“compounding.”

The first thermoplastic composition and second thermoplastic compositioncan independently further comprise a solid non-polymeric material suchas a chemical blowing agent, nucleating agent, filler, pigment, or acombination thereof. The solid non-polymeric material can be present inan amount from about 0.05 weight percent to about 20 weight percentbased on the total weight of the first thermoplastic composition and/orsecond thermoplastic composition; about 0.1 weight percent to about 10weight percent based on the total weight of the first thermoplasticcomposition and/or second thermoplastic composition; or 0.5 weightpercent to about 5 weight percent based on the total weight of the firstthermoplastic composition and/or second thermoplastic composition. Thefirst or the second thermoplastic composition can comprise about 5weight percent or less, or about 3 weight percent or less, or about 2weight percent or less, or about 1 weight percent or less of solidnon-polymeric material, based on the total weight of the firstthermoplastic composition and/or second thermoplastic composition. Thefoamed polymeric material can comprise less than about 5 weight percent,or less than 4 weight percent, or less than 3 weight percent, or lessthan 2 weight percent, or less than 1 weight percent of solidnon-polymeric material, based on the total weight of the firstthermoplastic composition and/or second thermoplastic composition.

The first thermoplastic composition and/or second thermoplasticcomposition can comprise essentially no, or can comprise nonon-polymeric materials such as chemical blowing agents, nucleatingagents, fillers, pigments, or a combination thereof. In other words, thefirst thermoplastic composition and/or second thermoplastic compositioncan be essentially free of non-polymeric materials. In other aspects,the first thermoplastic composition and/or second thermoplasticcomposition can comprise 5 weight percent or less of a non-polymericmaterial such as a chemical blowing agent, nucleating agent, filler,pigment, or a combination thereof. The first thermoplastic compositionand/or second thermoplastic composition can comprise less than 4 weightpercent, less than 3 weight percent, less than 2 weight percent, lessthan 1 weight percent, less than 0.5 weight percent, less than 0.1weight percent, less than 0.08 weight percent, less 0.06 weight percent,less than 0.04 weight percent, or less than 0.02 weight percent ofnon-polymeric material, based on a total weight of the firstthermoplastic composition and/or second thermoplastic composition. Inother aspects, the first thermoplastic composition and/or secondthermoplastic composition is free of (i.e., contains no) non-polymericmaterial such as a chemical blowing agent, nucleating agent, filler, ora combination thereof.

In some instances, the solid non-polymeric material is a filler. Thefiller can be a particulate filler. In further aspects, the filler is acarbonaceous filler. The carbonaceous filler can be carbon black,activated carbon, graphite, carbon fibers, carbon fibrils, carbonnanoparticles, or combinations thereof. In various aspects, thecarbonaceous filler can be chemically-modified. Alternatively, thefiller can be an inorganic filler. The inorganic filler can be an oxide,a hydroxide, a salt, a silicate, a metal, or combinations thereof.Examples of an inorganic filler include, but are not limited to, glassspheres, glass fibers, glass hollow spheres, glass flakes, MgO, SiO₂,SB₂O₃, Al₂O₃, ZnO, talc, mica, kaolin, wollastonite, or combinationsthereof.

Nucleating agents are widely used to modify the properties of variouspolymers. Nucleating agents can aid in decreasing foam specific gravity,increasing the number of cells present in the foam, and decreasing cellsize in the foam by providing a surface for heterogeneous nucleation ofgas bubbles from the supercritical fluid state. For the firstthermoplastic compositions and second thermoplastic compositions of thepresent disclosure, nucleating agents can influence the properties ofthe final foam article by modifying the quantity, distribution and rateof supercritical fluid conversion from a liquid to a gas during thefoaming process as lower pressures. The addition of nucleating agentsprovides a surface on which the supercritical fluid can be transformedfrom a liquid to a gas. As a consequence, many nucleation sites willresult in many gas cell domains. In a particular example, the nucleatingagent can include a metal salt of a fatty acid. In some aspects, thenucleating agent is zinc stearate. In some aspects, the composition ormaterial contains about 0.1 weight percent to about 10 weight percent,about 0.1 weight percent to about 5 weight percent, about 0.1 weightpercent to about 2 weight percent, or about 0.5 weight percent to about2 weight percent of the nucleating agent based upon a total weight ofthe composition or material.

In some aspects, the additive is a nucleating agent such as talcum,metal oxides such as titanium dioxide or magnesium oxide, phosphates,carbonates or sulfates of, preferably, alkaline earth metals, ormixtures thereof. Alternatively, the nucleating agent can be a mono- orpolycarboxylic acids, and the salts thereof, e.g., 4-tert-butylbenzoicacid, adipic acid, diphenylacetic acid, sodium succinate, sodiumbenzoate, or mixtures thereof. In a further aspect, the additive can bea nucleating agent comprising both an inorganic and an organic materialas disclosed herein above.

In some aspects, the rheology modifier can be a nano-particles havingcomparatively high aspect ratios, nano-clays, nano-carbon, graphite,nano-silica, and the like.

In some aspects, the additive is a filler or reinforcing agent such asclay, kaolin, talc, asbestos, graphite, glass (such as glass fibers,glass particulates, and glass bulbs, spheres, or spheroids), mica,calcium metasilicate, barium sulfate, zinc sulfide, aluminum hydroxide,silicates, diatomaceous earth, carbonates (such as calcium carbonate,magnesium carbonate and the like), metals (such as titanium, tungsten,zinc, aluminum, bismuth, nickel, molybdenum, iron, copper, brass, boron,bronze, cobalt, beryllium, and alloys of these), metal oxides (such aszinc oxide, iron oxide, aluminum oxide, titanium oxide, magnesium oxide,zirconium oxide and the like), metal hydroxides, particulate syntheticplastics (such as polyethylene, polypropylene, polystyrene, polyamide,polyester, polyurethane, polyimide, and the like), synthetic fibers(such as fibers comprising high molecular weight polyethylene,polypropylene, polystyrene, polyamide, polyester, polyurethane,polyimide, and the like), particulate carbonaceous materials (such ascarbon black and the like), wood flour and flours or fibers of othernatural products, as well as cotton flock, non-cotton cellulose flock,cellulose pulp, leather fiber, and combinations of any of the above.Non-limiting examples of heavy density filler components that can beused to increase the specific gravity of the cured elastomer compositioncan include titanium, tungsten, aluminum, bismuth, nickel, molybdenum,iron, steel, lead, copper, brass, boron, boron carbide whiskers, bronze,cobalt, beryllium, zinc, tin, metal oxides (such as zinc oxide, ironoxide, aluminum oxide, titanium oxide, magnesium oxide, and zirconiumoxide), metal sulfates (such as barium sulfate), metal carbonates (suchas calcium carbonate), and combinations of these. Non-limiting examplesof light density filler components that can be used to decrease thespecific gravity of the elastomer compound can include particulateplastics, hollow glass spheres, ceramics, and hollow spheres, regrinds,and foams, which can be used in combinations.

In some examples, the non-polymeric materials can also include ananofiller. Nanofillers can not only serve as mechanical reinforcementbut also nucleating agents. A variety of nanofillers can be used in lieuof or in addition to the zinc stearate. Nanofillers can includenanomaterials having one-dimensional structures such as of plates,laminas and/or shells; two-dimensional structures such as nanotubes andnanofibres having a diameter lower than 0.1 micrometer; orthree-dimensional nanostructures such as nanoparticles or beads.Nanoplate fillers can be natural or synthetic clays, as well asphosphates of transition metals. Clay-based nanocomposites generate anoverall improvement in physical performances. The most widely used onesare the phyllosilicates. Nanofillers can include nano-oxides such asnanoparticles of Titanium dioxide or Rutile. Other nanofillers caninclude nanoparticles of alumina or aluminum oxide, diatomite, andnanoscale carbon materials such as single-wall carbon nanotubes (SWCNT)or double-wall carbon nanotubes (DWCNT).

Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this disclosure belongs. It will be further understoodthat terms, such as those defined in commonly used dictionaries, shouldbe interpreted as having a meaning that is consistent with their meaningin the context of the specification and relevant art and should not beinterpreted in an idealized or overly formal sense unless expresslydefined herein.

The terms “comprises,” “comprising,” “including,” and “having,” areinclusive and therefore specify the presence of features, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, steps, operations,elements, components, and/or groups thereof.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a foam particle,”“a midsole,” or “an adhesive,” including, but not limited to, two ormore such foam particles, midsoles, or adhesives, and the like.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items.

As used herein, in substance or substantially means at least 50 percent,60 percent, 75 percent, 90 percent, 95 percent, or more, as determinedbased on weight or volume.

The terms first, second, third, etc. can be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms can be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

As used herein, the modifiers “upper,” “lower,” “top,” “bottom,”“upward,” “downward,” “vertical,” “horizontal,” “longitudinal,”“transverse,” “front,” “back” etc., unless otherwise defined or madeclear from the disclosure, are relative terms meant to place the variousstructures or orientations of the structures of the article of footwearin the context of an article of footwear worn by a user standing on aflat, horizontal surface.

The term “receiving”, such as for “receiving an upper for an article offootwear”, when recited in the claims, is not intended to require anyparticular delivery or receipt of the received item. Rather, the term“receiving” is merely used to recite items that will be referred to insubsequent elements of the claim(s), for purposes of clarity and ease ofreadability.

The terms “at least one” and “one or more of” an element are usedinterchangeably, and have the same meaning that includes a singleelement and a plurality of the elements, and can also be represented bythe suffix “(s)” at the end of the element. For example, “at least onepolyamide”, “one or more polyamides”, and “polyamide(s)” can be usedinterchangeably and have the same meaning.

It should be noted that ratios, concentrations, amounts, and othernumerical data can be expressed herein in a range format. Where thestated range includes one or both of the limits, ranges excluding eitheror both of those included limits are also included in the disclosure,e.g. the phrase “x to y” includes the range from ‘x’ to ‘y’ as well asthe range greater than ‘x’ and less than ‘y’. The range can also beexpressed as an upper limit, e.g. ‘about x, y, z, or less’ and should beinterpreted to include the specific ranges of ‘about x’, ‘about y’, and‘about z’ as well as the ranges of ‘less than x’, less than y′, and‘less than z’. Likewise, the phrase ‘about x, y, z, or greater’ shouldbe interpreted to include the specific ranges of ‘about x’, ‘about y’,and ‘about z’ as well as the ranges of ‘greater than x’, greater thany′, and ‘greater than z’. In addition, the phrase “about ‘x’ to ‘y’”,where ‘x’ and ‘y’ are numerical values, includes “about ‘x’ to about‘y’”. It is to be understood that such a range format is used forconvenience and brevity, and thus, should be interpreted in a flexiblemanner to include not only the numerical values explicitly recited asthe limits of the range, but also to include all the individualnumerical values or sub-ranges encompassed within that range as if eachnumerical value and sub-range is explicitly recited. To illustrate, anumerical range of “about 0.1% to 5%” should be interpreted to includenot only the explicitly recited values of about 0.1 percent to about 5percent, but also include individual values (e.g., 1 percent, 2 percent,3 percent, and 4 percent) and the sub-ranges (e.g., 0.5 percent, 1.1percent, 2.4 percent, 3.2 percent, and 4.4 percent) within the indicatedrange.

The terms “about” and “substantially” are used herein with respect tomeasurable values and ranges due to expected variations known to thoseskilled in the art (e.g., limitations and variabilities inmeasurements).

As used herein, the terms “optional” or “optionally” means that thesubsequently described component, event or circumstance can or cannotoccur, and that the description includes instances where said component,event or circumstance occurs and instances where it does not.

As used herein, the term “units” can be used to refer to individual(co)monomer units such that, for example, styrenic repeat units refersto individual styrene (co)monomer units in the polymer. In addition, theterm “units” can be used to refer to polymeric block units such that,for example, “styrene repeating units” can also refer to polystyreneblocks; “units of polyethylene” refers to block units of polyethylene;“units of polypropylene” refers to block units of polypropylene; “unitsof polybutylene” refers to block units of polybutylene, and so on. Suchuse will be clear from the context.

The term “copolymer” refers to a polymer having two or more monomerspecies, and includes terpolymers (i.e., copolymers having three monomerspecies).

Reference to “a” chemical compound refers one or more molecules of thechemical compound, rather than being limited to a single molecule of thechemical compound. Furthermore, the one or more molecules may or may notbe identical, so long as they fall under the category of the chemicalcompound. Thus, for example, “a” polyamide is interpreted to include oneor more polymer molecules of the polyamide, where the polymer moleculesmay or may not be identical (e.g., different molecular weights and/orisomers).

As used herein the terms “percent by weight” or “weight percent,” whichcan be used interchangeably, indicate the weight percent of a givencomponent based on the total weight of the composition or article,unless otherwise specified. That is, unless otherwise specified, allweight percent values are based on the total weight of the composition.It should be understood that the sum of weight percent values for allcomponents in a disclosed composition or formulation or article areequal to 100.

Similarly, the terms “percent by volume” or “volume percent,” which canbe used interchangeably, indicate the percent by volume of a givencomponent based on the total volume of the composition or article,unless otherwise specified. That is, unless otherwise specified, allvolume percent values are based on the total volume of the compositionor article. It should be understood that the sum of volume percentvalues for all components in a disclosed composition or formulation orarticle are equal to 100.

Compounds are described using standard nomenclature. For example, anyposition not substituted by any indicated group is understood to haveits valence filled by a bond as indicated, or a hydrogen atom. A dash(“—”) that is not between two letters or symbols is used to indicate apoint of attachment for a substituent. For example, —CHO is attachedthrough carbon of the carbonyl group. Unless defined otherwise,technical and scientific terms used herein have the same meaning as iscommonly understood by one of skill in the art to which this inventionbelongs.

Unless otherwise specified, temperatures referred to herein are based onatmospheric pressure (i.e. one atmosphere).

Before proceeding to the Examples, it is to be understood that thisdisclosure is not limited to particular aspects described, and as suchmay, of course, vary. Other systems, methods, features, and advantagesof foam compositions and components thereof will be or become apparentto one with skill in the art upon examination of the following drawingsand detailed description. It is intended that all such additionalsystems, methods, features, and advantages be included within thisdescription, be within the scope of the present disclosure, and beprotected by the accompanying claims. It is also to be understood thatthe terminology used herein is for the purpose of describing particularaspects only, and is not intended to be limiting. The skilled artisanwill recognize many variants and adaptations of the aspects describedherein. These variants and adaptations are intended to be included inthe teachings of this disclosure and to be encompassed by the claimsherein.

Test Methods

Below are certain sampling procedures and testing methods referenced inthe Description and in the Examples.

Sampling Procedures

Various properties of the compositions and foams and other articlesformed therefrom can be characterized using samples prepared with thefollowing sampling procedures:

a. Neat Sampling Procedure

The neat sampling procedure can be used to obtain a neat sample of afoamed or unfoamed first thermoplastic composition, an unfoamed orfoamed second thermoplastic composition, or, in some instances, a sampleof a material (e.g., polymer) used to form a first thermoplasticcomposition or second thermoplastic composition. The material can beprovided in media form, such as flakes, granules, powders, pellets, andthe like. If a source of the first thermoplastic composition or secondthermoplastic composition is not available in a neat form, the samplecan be cut from another component containing the composition ormaterial, thereby isolating a sample of the composition or material.

b. Plaque Sampling Procedure—Solid Composition or Material

The first thermoplastic composition or second thermoplastic compositionis molded into a plaque having dimensions of about six inches by about 4inches and a thickness of about 20 millimeters (or as otherwisespecified by the test method). The sample is prepared by mixing togetherthe components of the composition or material, melting the compositionor material, pouring, extruding, or injecting the melted compositioninto a mold cavity, cooling the melted composition or material tosolidify it in the mold cavity to form the plaque, and then removing theplaque from the mold cavity.

c. Plaque Sampling Procedure—Foam Composition or Material

The foamed first thermoplastic composition or second thermoplasticcomposition is foamed into a sheet. The skin is removed from a portionof the sheet, and the skinned portion of the sheet is cut into a plaquehaving dimensions of about six inches by about four inches and athickness of about 20 millimeter (mm) (or as otherwise specified by thetest method).

d. Component Sampling Procedure

This procedure can be used to obtain a sample of a foamed or unfoamedcomposition or material when the composition or material is incorporatedinto a component such as a sole structure or midsole or outsole of anarticle of footwear. A sample of the component which includes thecomposition or material is obtained as formed into the component, or cutfrom the article of footwear using a blade. This process is performed byseparating the component from an associated footwear upper, if present,and removing any materials from the article's top surface (e.g.,corresponding to the top surface). For example, the article's topsurface can be skinned, abraded, scraped, or otherwise cleaned to removeany upper adhesives, yarns, fibers, foams, and the like that couldpotentially interfere with the test results.

The resulting component sample includes the composition or material. Assuch, any test using a Component Sampling Procedure can simulate how thecomposition or material will perform as part of an article of footwear.As specified by the test method, the component may be tested as a fullcomponent (e.g., full midsole component), or it can be extracted as asample having a certain geometry. A sample of a component is taken at alocation along the component that provides a substantially constantthickness for the component (within plus or minus 10 percent of theaverage thickness), such as in a forefoot region, mid-foot region, or aheel region of the article. Unless otherwise specified, the desiredharvested geometry is a cylindrical puck with a 45-millimeter diameterand a cylinder height of at least about 10 millimeters, preferably fromabout 20 to 25 millimeters. Compression testing of the harvestedcomponent samples should be tested along the length of the cylinderusing compression platens that are at least twice the diameter of thecylindrical puck sample.

Solid Polymer, Thermoplastic Copolyester Composition, and SecondThermoplastic composition Characterization.

Glass Transition Temperature, Melting Temperature, and CrystallizationTemperature Test

Dynamic scanning calorimetry (DSC) is performed on samples preparedusing the Neat Sampling Procedure, or on a portion of a sample preparedusing the Plaque Sampling Procedure or the Component Sampling Procedure.The test is conducted using a DSC system such as a TA instruments Q2000.10-30 mg samples are cycled from negative 90 degrees centigrade to 225degrees centigrade at a rate of 20 degrees centigrade/min and cooled tonegative 90 degrees centigrade at a rate of 10 degrees centigrade/min.Each sample is run in duplicate. The melting temperature,crystallization temperature, and glass transition temperature values arerecorded from the second cycle. The melt, crystallization, or glasstransition “peak” is identified as the local maximum of the secondheating cycle. If there was more than one melt peak in the DSC curve,the melt peak occurring at hotter temperatures was chosen as theinjecting or foaming temperature reference. The tail was identified asthe intersection of the tangent of the line of the higher temperatureside of the melt peak with the extrapolated baseline. A schematicillustrating the method for determining peak and tail temperatures isshown in FIG. 8.

Cyclic Tensile Test

The cyclic tensile testing is carried out on solid samples preparedusing the Plaque Sampling Procedure or the Component Sampling Procedure,having a dog-bone shape as described in ASTM D638 with a 2 mm thickness.In the test, the specimen is placed under a pre-load of 5 N. Strain iscontrolled to extend the sample to an extension 6 percent at a strainrate of 5 Hz. The stiffness is the load at 6 percent strain divided bythe extension at 6 percent strain, giving a value in N/mm. The maximumload (N) observed over the test cycle of 500 cycles is also recorded.

Melt Flow Index Test

The melt flow index is determined using a sample prepared using the NeatSampling Procedure, or on a portion of a sample prepared using thePlaque Sampling Procedure or the Component Sampling Procedure, accordingto the test method detailed in ASTM D1238-13 Standard Test Method forMelt Flow Rates of Thermoplastics by Extrusion Plastometer, usingProcedure A described therein. Briefly, the melt flow index measures therate of extrusion of thermoplastics through an orifice at a prescribedtemperature and load. In the test method, approximately 7 grams of thesample is loaded into the barrel of the melt flow apparatus, which hasbeen heated to a specified temperature of 210 degrees centigrade, 220degrees centigrade, or 230 degrees centigrade. A weight of 2.16kilograms is applied to a plunger and the molten sample is forcedthrough the die. A timed extrudate is collected and weighed. Melt flowrate values are calculated in g/10 min, and are reported with thespecified temperature (i.e., 210, 220 or 230 degrees centigrade) and theweight applied to the plunger (i.e., 2.15 kilograms).

Solid Polymer Abrasion Test (Akron)

Abrasion loss is tested on a sample sheet having a thickness of 3millimeters, prepared using the Plaque Sampling procedure or theComponent Sampling Procedure. The sample sheet is adhered onto an Akronabrasion test specimen with JIS-A hardness of 70 by using an adhesive toprepare a test specimen. Abrasion loss in volume is measured by using anAkron abrasion test machine at a load of 27 N, an inclination angle of15 degree, a preliminary abrasion of 500 times and a test abrasion of1,000 times according to JIS K6254. The mass and/or volume of the sampleis measured before and after the test, with the difference being theabrasion loss. The smaller the abrasion loss volume or mass, the betterthe abrasion resistance.

Solid Polymer Abrasion Test (DIN)

Abrasion loss is tested on samples cut from sheets having a minimumthickness of 6 millimeters to 12 millimeters, prepared using the PlaqueSampling Procedure or the Component Sampling Procedure. The cut sampleshave a cylindrical shape with a diameter of 16 millimeters plus or minus0.2 millimeters and a minimum thickness of 6 mm to 12 mm cut from sheetsusing an ASTM standard hole drill. The abrasion loss is measured usingMethod B of ASTM D 5963-97a on a standard abrasion test machine such asa Gotech GT-7012-D abrasion test machine. The tests are performed at 22degrees centigrade with an abrasion path of 40 meters. The sample isabraded with a standard sandpaper such as VSM-VITEX-KK511X-60P sandpaper(commercially available from VSM Abrasives Corp.), using an abrasionload of 10 Newton. The mass and/or volume of the sample is measuredbefore and after the test, with the difference being the abrasion loss.The smaller the abrasion loss, the better the abrasion resistance of thematerial.

Solid Polymer Coefficient of Friction Test (Wet & Dry)

This test measures the coefficient of friction of the Coefficient ofFriction Test for a sample (e.g., taken with the above-discussedComponent Sampling Procedure, Plaque Sampling Procedure, or the NeatSampling Procedure). The sample is cut into a rectangular shapemeasuring approximately 3.0 inches by 3.3 inches, and having a thicknessof about 2 millimeters. The sample is permanently adhered to a 1centimeter thick piece of EVA foam having a density of approximately0.25 grams/cubic centimeters and having a Durometer hardness of 50 C.

For a dry test (i.e., to determine a dry-state coefficient of friction),the sample is initially equilibrated at 25 degree C. and 20 percenthumidity for 24 hours. For a wet test (i.e., to determine a wet-statecoefficient of friction), the sample is fully immersed in a deionizedwater bath maintained at 25 degree C. for 24 hours. After that, thesample is removed from the bath and blotted with a cloth to removesurface water.

The measurement is performed with an aluminum sled mounted on a testtrack, which is used to perform a sliding friction test for test sampleon the surface of the test track. The surface of the test track mayinclude a specified test track material, such as aluminum, wood courtsurface (wet or dry), smooth concrete surface (wet or dry). The testtrack measures 127 millimeters wide by 610 millimeters long. Thealuminum sled measures 76.2 millimeters by 76.2 millimeters, with a 9.5millimeter radius cut into the leading edge. The contact area of thealuminum sled with the track is 76.2 millimeters by 66.6 millimeters, or5,100 square millimeters).

The dry or wet sample is attached to the bottom of the sled using a roomtemperature-curing two-part epoxy adhesive such as the adhesivecommercially available under the tradename “LOCTITE 608” from Henkel,Dusseldorf, Germany. The adhesive is used to maintain the planarity ofthe wet sample, which can curl when saturated. A polystyrene foam havinga thickness of about 25.4 millimeters is attached to the top surface ofthe sled (opposite of the test sample) for structural support.

The sliding friction test is conducted using a screw-driven load frame.A tow cable is attached to the sled with a mount supported in thepolystyrene foam structural support, and is wrapped around a pulley todrag the sled across the aluminum test track. The sliding or frictionalforce is measured using a load transducer with a capacity of 2,000Newtons. The normal force is controlled by placing weights on top of thealuminum sled, supported by the foam structural support, for a totalsled weight of 1000 Newtons). The crosshead of the test frame has aspeed of 0.4 meters/second, and the total test displacement is 250millimeters. The coefficient of friction is calculated based on thesteady-state force parallel to the direction of movement required topull the sled at constant velocity. The coefficient of friction itselfis found by dividing the steady-state pull force by the applied normalforce. Any transient value relating static coefficient of friction atthe start of the test is ignored.

Ply Adhesion Testing

Ply adhesion testing determines the adhesion between two bonded plies ofmaterial (e.g., a thermoplastic copolyester composition and a secondthermoplastic composition) using a tensile testing device such as anInstron Electropuls E10000 (Instron, Norwood, Mass., USA). Sample pliesof each material may be provided using the Neat Sampling Procedure orthe Plaque Sampling Procedure or Component Sampling Procedure, and theplies are thereafter bonded using a specified method. Alternatively, asample of bonded plies may be provided by using the Component SamplingProcedure. On one end of the sample, the bond between the plies iscarefully separated to provide approximately 0.5 centimeter unbondedlength that may be inserted into the crossheads of the tensile testingdevice. A first ply is inserted into a first grip of the tensile tester,and a second ply is inserted into a second grip of the tensile tester sothat the sample between the grips is substantially straight. Thecrosshead speed is set to 50 millimeters per minute. The peel strengthis measured throughout the separation of the bonded sample until thebond fully separates or the sample fails. The force per peel distance isreported (kilograms force/centimeter), and the mode of failure (eitheradhesive or cohesive) is recorded for each sample.

Foam Characterization.

Density Test

The density is measured for samples taken using the Plaque SamplingProcedure, or the Component Sampling Procedure, using a digital balanceor a Densicom Tester (Qualitest, Plantation, Fla., USA). For each samplea sample volume is determined in cubic centimeters, and then each sampleis weighed (g). The density of the sample is the mass divided by thesample volume, given in grams/cubic centimeters.

Specific Gravity Test

The specific gravity (SG) is measured for samples taken using the PlaqueSampling Procedure, or the Component Sampling Procedure, using a digitalbalance or a Densicom Tester (Qualitest, Plantation, Fla., USA). Eachsample is weighed (g) and then is submerged in a distilled water bath(at 22 degrees centigrade plus or minus 2 degrees centigrade). To avoiderrors, air bubbles on the surface of the samples are removed, e.g., bywiping isopropyl alcohol on the sample before immersing the sample inwater, or using a brush after the sample is immersed. The weight of thesample in the distilled water is recorded. The specific gravity iscalculated with the following formula:

${S.G.} = \frac{{Weight}\mspace{14mu} {of}\mspace{14mu} {the}\mspace{14mu} {sample}\mspace{14mu} {in}\mspace{14mu} {air}\mspace{14mu} (g)}{{{Weight}\mspace{14mu} {of}\mspace{14mu} {sample}\mspace{14mu} {in}\mspace{14mu} {air}\mspace{14mu} (g)} - {{Weight}\mspace{14mu} {of}\mspace{14mu} {sample}\mspace{14mu} {in}\mspace{14mu} {water}\mspace{14mu} (g)}}$

Water Uptake Test

This test measures the water uptake capacity of a foam sample after asoaking duration of 5 minutes. A 1-centimeter core sample is removedfrom a foam sample prepared using the Plaque Sampling Procedure orComponent Sampling Procedure, starting from the side wall of the foamedarticle, e.g., the midsole of an article of footwear. The core is thencut to provide a cylindrical sample having a 1-centimeter cylinderheight, ensuring that the side wall remains as part of the core sample.The sample is conditioned in an oven for 24 hours at 50 degreescentigrade plus or minus 3 degrees centigrade. After conditioning, thesample is cooled for 30 minutes in a lab environment at a temperature of22 degrees centigrade plus or minus 2 degrees centigrade, and then isimmediately weighed, and the weight recorded in grams (W_0). The surfaceof the side wall is masked with masking tape, while all other surfacesare sealed with a nonpermeable coating. When the surfaces are fullycoated, the sidewall surface is unmasked. The coated sample is thenconditioned in an oven for 24 hours at 50 degrees centigrade plus orminus 3 degrees centigrade, cooled for 30 minutes in a lab environmentat a temperature of 22 degrees centigrade plus or minus 2 degreescentigrade, and then is immediately weighed and the weight recorded ingrams (W_i). The dried sample is fully immersed in a deionized waterbath maintained at 22 degrees centigrade plus or minus 2 degreescentigrade, for a duration of 2 hours. After the soaking duration, thesample is removed from the deionized water bath, blotted with a cloth toremove surface water, and the total weight of the soaked sample (W_f) ismeasured in grams (W_f). The water uptake for the time period iscalculated as follows:

${{Water}\mspace{14mu} {Uptake}\mspace{14mu} {Capacity}} = {\frac{{W\_ f} - {W\_ i}}{W\_ i} \times 100\%}$

Force/Displacement Test (Cyclic Compression Test)

Force/displacement behavior for the foams and the foamed articles ismeasured using samples having a diameter of 45 millimeters and athickness of at least 10 millimeters (preferably 20 to 25 millimeters)prepared using the Plaque Sampling Procedure or the Component SamplingProcedure with a cyclic compression testing device such an InstronElectropuls E10000 (Instron, Norwood, Mass., USA) with a stainless steelcircular cross section impact geometry having a diameter at least twicethe diameter of the foam sample (e.g., for a 45-millimeter diametersample, a 90-millimeter diameter platen). Each sample is compressed to50% strain at 5 Hz for 500 cycles. Stiffness, efficiency, and energyreturn are measured from the force vs. displacement curves for cycles200, 300, 400, and 500. Stiffness of a particular foam sample is thestress at the maximum strain divided by the maximum strain, giving avalue in kPa or N/mm. Efficiency of a foam sample is the integral of theunloading force-displacement curve divided by the integral of theloading force-displacement curve. Energy return of a foam sample is theintegral of the unloading force-displacement curve, giving a value inmJ. The reported value for each metric is the average of each metricbetween cycles 200, 300, 400, and 500. All fatigue metrics are definedas relative differences in properties at the end of the test compared tothe same properties at the beginning of the test (i.e., cycle 1).

In some cases, a full midsole is tested using a footform for impactinstead of a cylindrical tupp to more accurately simulate full gateloading. For these tests, a US mens size 10 midsole is tested, and amens size 9 footform used for impact, with a load of 2000 N beingapplied to the midsole with the footform at a loading rate of 5 Hz. Allof the metrics from the footform test are collected and analyzed asdescribed above.

As with when a cylindrical tupp is used, when a footform is used, energyinput is taken as the integral of the force-displacement curve duringcompression force loading. Energy return is taken as the integral of theforce displacement curve during unloading. Hysteresis is taken as theratio: (energy return)/(energy input), which can also be viewed as theenergy efficiency of the foam. Fatigue behavior is judged by changes inthe foam displacement at the max load of a cycle. All measuredproperties: stiffness, hysteresis, and fatigue are measured forthousands of cycles for both running and walking compression cycles.

Durometer Hardness Test—Shore A

The test used to obtain the hardness values for the foam articles is asfollows. A flat foam sample is prepared using the Plaque SamplingProcedure or the Component Sampling Procedure, where the sample has aminimum of 6 mm thick for Shore A durometer testing. If necessary,samples are stacked to make up the minimum thickness. Samples are largeenough to allow all measurements to be performed at a minimum of 12 mmfrom the edge of the sample and at least 12 mm from any othermeasurement. Regions tested are flat and parallel with an area at least6 mm in diameter. A minimum of five hardness measurements are taken andtested using a 1 kilogram head weight.

Split Tear Test

The split tear test can determine the internal tear strength for a foammaterial. A sample may be provided either using the Plaque SamplingProcedure or the Component Sampling Procedure. The sample is die cutinto a rectangular shape having a width of 1.54 centimeters and a lengthof 15.24 centimeters (1 inch by 6 inches), and having a thickness of 10millimeters, plus or minus 1 millimeter. On one end, a cut is made intothe sample that bisects the thickness, the cut extending the full widthof the sample, and 3 centimeters from the end of the sample. Startingfrom the end of the cut, 5 marks are placed along the length of thesample spaced 2 centimeters apart. The cut ends of the sample are placedin the clamps of a tensile tester. Each section of the sample is held ina clamp in such a manner that the original adjacent cut edges form astraight line joining the centers of the clamps. The crosshead speed isset to 50 millimeters per minute. The tear strength is measuredthroughout the separation of the crossheads. If necessary, a sharp knifemay be used to keep separating the foam in the center of the sample,discarding the readings caused by cutting of the knife. The lowest splittear strength values are recorded for each of the five marked segmentsof the sample (between each of the 2-centimeter markings). An averagesplit tear strength value is recorded for each sample. If a segment of asample has an air bubble measuring more than 2 millimeters, the tearstrength for the segment is discarded, and the air bubble recorded as atest defect. If more than one segment of a sample has an air bubblemeasuring more than 2 millimeters, the entire sample is discarded.

Hand Pull Test

The hand pull test can evaluate the bond strength between two foams,compositions or materials, such as between a solid and a foam or betweentwo different foams. Depending upon the bonding method used, a sample oftwo pre-bonded foams, compositions or materials may be provided eitherusing the Plaque Sampling Procedure or the Component Sampling Procedure.Alternatively, separate samples of a foam, a composition or a materialcan be prepared using the Plaque Sampling Procedure or the ComponentSampling Procedure, and then can be bonded together using the bondingmethod to be evaluated. The sample is die cut into a rectangular shapehaving a width of 1.54 centimeters and a length of 15.24 centimeters (1inch by 6 inches), and having a thickness of 10 millimeters, plus orminus 1 millimeter. On one end, a cut is made into the sample thatbisects the thickness, the cut extending the full width of the sample,and 3 centimeters from the end of the sample. Starting from the end ofthe cut, 5 marks are placed along the length of the sample spaced 2centimeters apart. The cut ends of the sample are held in the tester'shand and pulled at a rate of approximately 50 millimeters per minute. Ifnecessary, a sharp knife may be used to keep separating the material inthe center of the sample, discarding the readings caused by cutting ofthe knife. Tear strength values are recorded for each of the five markedsegments of the sample (between each of the 2-centimeter markings),using the following scoring rubric: easy to peel or adhesive failure isgiven a score of 1; an adhesive failure but some resistance is given ascore of 2; cohesive foam failure is given a score of 3 to 4.5 based onthe accompanying level of foam skin failure, where 3 is the highestlevel of foam skin failure and 4.5 is the lowest level of foam skinfailure; and unable to separate is given a score of 5. The scores foreach segment are averaged to give value recorded for each sample. If asegment of a sample has an air bubble measuring more than 2 millimeters,the tear strength for the segment is discarded, and the air bubblerecorded as a test defect. If more than one segment of a sample has anair bubble measuring more than 2 millimeters, the entire sample isdiscarded.

ASPECTS

The following listing of exemplary aspects supports and is supported bythe disclosure provided herein.

Aspect 1. A foam article comprising:a first foam component having an exterior surface, the foam componentcomprising a foamed first thermoplastic composition comprising a firstthermoplastic copolyester elastomer having a multicellular foamstructure; anda polymeric layer comprising a second thermoplastic compositioncomprising a second thermoplastic elastomer, and the polymeric layer isdisposed on at least a portion of the exterior surface of the first foamcomponent;wherein the first thermoplastic composition is structurally differentthan the second thermoplastic composition.Aspect 2. A foam article comprising:a first foam component having an exterior surface, the foam componentcomprising a foamed first thermoplastic composition, wherein the foamedfirst thermoplastic composition is a multicellular foam having an opencell foam microstructure; anda polymeric layer comprising a second thermoplastic composition disposedon at least a portion of the exterior surface of the first foamcomponent;wherein the polymeric layer forms a water-resistant barrier on the atleast a portion of the exterior surface of the first foam component.Aspect 3. The foam article of Aspects 1-2, wherein the foamed firstthermoplastic composition comprises a thermoplastic copolyester.Aspect 4. The foam article of any one of Aspects 1-3, wherein the foamedfirst thermoplastic composition comprises greater than 95 weight percentof a thermoplastic copolyester composition according to any one ofAspects 9-99, based on the total weight of the foamed firstthermoplastic composition.Aspect 5. The foam article of Aspect 1, wherein the foam componentcomprises an open-cell microstructure.Aspect 6. The foam article of any one of Aspects 1-5, wherein less than10 percent of the cells in the foam microstructure comprise closedcells.Aspect 7. The foam article of any one of Aspects 1-5, wherein less than5 percent of the cells in the foam microstructure comprise closed cells.Aspect 8. The foam article of any one of Aspects 1-5, wherein less than1 percent of the cells in the foam microstructure comprise closed cells.Aspect 9. The foam article of any one of Aspects 1-8, wherein the firstthermoplastic composition comprises a thermoplastic copolyestercomprising:

-   -   a plurality of first segments, each first segment derived from a        dihydroxy-terminated polydiol;    -   a plurality of second segments, each second segment derived from        a diol; and        a plurality of third segments, each third segment derived from        an aromatic dicarboxylic acid.        Aspect 10. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester is a block copolymer.        Aspect 11. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester is a segmented copolymer.        Aspect 12. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester is a random copolymer.        Aspect 13. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester is a condensation copolymer.        Aspect 14. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a weight average molecular        weight of about 50,000 Daltons to about 1,000,000 Daltons.        Aspect 15. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a weight average molecular        weight of about 50,000 Daltons to about 500,000 Daltons.        Aspect 16. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a weight average molecular        weight of about 75,000 Daltons to about 300,000 Daltons.        Aspect 17. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a weight average molecular        weight of about 100,000 Daltons to about 200,000 Daltons.        Aspect 18. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a ratio of first segments to        third segments from about 1:1 to about 1:5 based on the weight        of each of the first segments and the third segments.        Aspect 19. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a ratio of first segments to        third segments from about 1:1 to about 1:3 based on the weight        of each of the first segments and the third segments.        Aspect 20. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a ratio of first segments to        third segments from about 1:1 to about 1:2 based on the weight        of each of the first segments and the third segments.        Aspect 21. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a ratio of second segments to        third segments from about 1:1 to about 1:3 based on the weight        of each of the first segments and the third segments.        Aspect 22. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a ratio of second segments to        third segments from about 1:1 to about 1:2 based on the weight        of each of the first segments and the third segments.        Aspect 23. The foam article of any one of Aspects 1-9, wherein        the thermoplastic copolyester has a ratio of second segments to        third segments from about 1:1 to about 1:1.52 based on the        weight of each of the first segments and the third segments.        Aspect 24. The foam article of any one of Aspects 1-9, wherein        the first segments derived from a dihydroxy-terminated polydiol        comprise segments derived from a poly(alkylene oxide)diol having        a number-average molecular weight of about 250 Daltons to about        6000 Daltons.        Aspect 25. The foam article of Aspect 24, wherein the        number-average molecular weight is about 400 Daltons to about        6,000 Daltons.        Aspect 26. The foam article of Aspect 24, wherein the        number-average molecular weight is about 350 Daltons to about        5,000 Daltons.        Aspect 27. The foam article of Aspect 24, wherein the        number-average molecular weight is about 500 Daltons to about        3,000 Daltons.        Aspect 28. The foam article of any one of Aspects 24-27, wherein        poly(alkylene oxide)diol is poly(ethylene ether)diol;        poly(propylene ether)diol; poly(tetramethylene ether)diol;        poly(pentamethylene ether)diol; poly(hexamethylene ether)diol;        poly(heptamethylene ether)diol; poly(octamethylene ether)diol;        poly(nonamethylene ether)diol; poly(decamethylene ether)diol; or        mixtures thereof.        Aspect 29. The foam article of any one of Aspects 24-28, wherein        poly(alkylene oxide)diol is poly(ethylene ether)diol;        poly(propylene ether)diol; poly(tetramethylene ether)diol;        poly(pentamethylene ether)diol; poly(hexamethylene ether)diol.        Aspect 30. The foam article of any one of Aspects 24-29, wherein        poly(alkylene oxide)diol is poly(tetramethylene ether)diol.        Aspect 31. The foam article of any one of Aspects 1-30, wherein        the second segments derived from a diol comprise a diol having a        molecular weight of less than about 250.        Aspect 32. The foam article of any one of Aspects 1-31, wherein        the diol is a C2-C8 diol.        Aspect 33. The foam article of any one of Aspects 1-32, wherein        the second segments derived from a diol comprise a diol selected        from ethanediol; propanediol; butanediol; pentanediol; 2-methyl        propanediol; 2,2-dimethyl propanediol; hexanediol; 1,2-dihydroxy        cyclohexane; 1,3-dihydroxy cyclohexane; 1,4-dihydroxy        cyclohexane; and mixtures thereof.        Aspect 34. The foam article of any one of Aspects 1-33, wherein        the diol is selected from 1,2-ethanediol, 1,3-propanediol,        1,4-butanediol, 1,6-hexanediol, and mixtures thereof.        Aspect 35. The foam article of any one of Aspects 1-33, wherein        the diol is 1,2-ethanediol.        Aspect 36. The foam article of any one of Aspects 1-33, wherein        the diol is 1,4-butanediol.        Aspect 37. The foam article of any one of Aspects 1-36, wherein        the third segments derived from an aromatic dicarboxylic acid        comprise an aromatic C5-C16 dicarboxylic acid.        Aspect 38. The foam article of Aspect 37, wherein the aromatic        C5-C16 dicarboxylic acid has a molecular weight less than about        300 Daltons.        Aspect 39. The foam article of any one of Aspects 37-38, wherein        the aromatic C5-C16 dicarboxylic acid has a molecular weight of        about 120 Daltons to about 200 Daltons.        Aspect 40. The foam article of any one of Aspects 37-39, wherein        the aromatic C5-C16 dicarboxylic acid is terephthalic acid,        phthalic acid, isophthalic acid, or a derivative thereof.        Aspect 41. The foam article of any one of Aspects 37-40, wherein        the derivative of the aromatic C5-C16 dicarboxylic acid is a        diester derivative of the terephthalic acid, phthalic acid, or        isophthalic acid.        Aspect 42. The foam article of any one of Aspects 37-41, wherein        the aromatic C5-C16 dicarboxylic acid is terephthalic acid or        the dimethyl ester derivative thereof.        Aspect 43. The foam article of any one of Aspects 1-42, wherein        the thermoplastic copolyester comprises:

-   (a) a plurality of first copolyester units, each first copolyester    unit of the plurality comprising the first segment derived from a    dihydroxy-terminated polydiol and the third segment derived from an    aromatic dicarboxylic acid, wherein the first copolyester unit has a    structure represented by a formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide) diol of the first segment, whereinthe poly(alkylene oxide) diol of the first segment is a poly(alkyleneoxide) diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and

-   (b) a plurality of second copolyester units, each second copolyester    unit of the plurality comprising the second segment derived from a    diol and the third segment derived from an aromatic dicarboxylic    acid, wherein the second copolyester unit has a structure    represented by a formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.Aspect 44. The foam article of Aspect 43, wherein the first copolyesterunit has a structure represented by a formula 3:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons.Aspect 45. The foam article of any one of Aspects 43-44, wherein y is aninteger having a value of 1, 2, 3, 4, or 5.Aspect 46. The foam article of any one of Aspects 43-45, wherein y is aninteger having a value of 1, 2, or 3.Aspect 47. The foam article of any one of Aspects 43-46, wherein R ishydrogen.Aspect 48. The foam article of any one of Aspects 43-46, wherein R ismethyl.Aspect 49. The foam article of any one of Aspects 43-46, wherein R ishydrogen and y is an integer having a value of 1, 2, or 3.Aspect 50. The foam article of any one of Aspects 43-46, wherein R ismethyl and y is an integer having a value of 1.Aspect 51. The foam article of Aspect 43, wherein the first copolyesterunit has a structure represented by a formula 4:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons.Aspect 52. The foam article of Aspect 50, wherein z is an integer havinga value from 5 to 60.Aspect 53. The foam article of any one of Aspects 51-52, wherein z is aninteger having a value from 5 to 50.Aspect 54. The foam article of any one of Aspects 51-53, wherein z is aninteger having a value from 5 to 40.Aspect 55. The foam article of any one of Aspects 51-54, wherein z is aninteger having a value from 4 to 30.Aspect 56. The foam article of any one of Aspects 51-55, wherein z is aninteger having a value from 4 to 20.Aspect 57. The foam article of any one of Aspects 51-53, wherein z is aninteger having a value from 2 to 10.Aspect 58. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 400 Daltons to about 6,000 Daltons.Aspect 59. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 400 Daltons to about 5,000 Daltons.Aspect 60. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 400 Daltons to about 4,000 Daltons.Aspect 61. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 400 Daltons to about 3,000 Daltons.Aspect 62. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 500 Daltons to about 6,000 Daltons.Aspect 63. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 500 Daltons to about 5,000 Daltons.Aspect 64. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 500 Daltons to about 4,000 Daltons.Aspect 65. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 500 Daltons to about 3,000 Daltons.Aspect 66. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 600 Daltons to about 6,000 Daltons.Aspect 67. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 600 Daltons to about 5,000 Daltons.Aspect 68. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 600 Daltons to about 4,000 Daltons.Aspect 69. The foam article of any one of Aspects 42-57, wherein theweight average molecular weight of each of the plurality of firstcopolyester units is from about 600 Daltons to about 3,000 Daltons.Aspect 70. The foam article of any one of Aspects 42-69, wherein thesecond copolyester unit has a structure represented by a formula 5:

wherein x is an integer having a value from 1 to 20.Aspect 71. The foam article of Aspect 70, wherein x is an integer havinga value from 2 to 18.Aspect 72. The foam article of Aspects 70-71, wherein x is an integerhaving a value from 2 to 17.Aspect 73. The foam article of any one of Aspects 70-72, wherein x is aninteger having a value from 2 to 16.Aspect 74. The foam article of any one of Aspects 70-73, wherein x is aninteger having a value from 2 to 15.Aspect 75. The foam article of any one of Aspects 70-74, wherein x is aninteger having a value from 2 to 14.Aspect 76. The foam article of any one of Aspects 70-75, wherein x is aninteger having a value from 2 to 13.Aspect 77. The foam article of any one of Aspects 70-76, wherein x is aninteger having a value from 2 to 12.Aspect 78. The foam article of any one of Aspects 70-77, wherein x is aninteger having a value from 2 to 11.Aspect 79. The foam article of any one of Aspects 70-78, wherein x is aninteger having a value from 2 to 10.Aspect 80. The foam article of any one of Aspects 70-79, wherein x is aninteger having a value from 2 to 9.Aspect 81. The foam article of any one of Aspects 70-80, wherein x is aninteger having a value from 2 to 8.Aspect 82. The foam article of any one of Aspects 70-81, wherein x is aninteger having a value from 2 to 7.Aspect 83. The foam article of any one of Aspects 70-82, wherein x is aninteger having a value from 2 to 6.Aspect 84. The foam article of any one of Aspects 70-83, wherein x is aninteger having a value of 2, 3, or 4.Aspect 85. The foam article of any one of Aspects 42-69, wherein thesecond copolyester unit has a structure represented by a formula 6:

Aspect 86. The foam article of any one of Aspects 42-85, wherein thethermoplastic copolyester comprises about 30 weight percent to about 80weight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 87. The foam article of any one of Aspects 42-86, wherein thethermoplastic copolyester comprises about 40 weight percent to about 80weight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 88. The foam article of any one of Aspects 42-87, wherein thethermoplastic copolyester comprises about 50 weight percent to about 80weight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 89. The foam article of any one of Aspects 42-88, wherein thethermoplastic copolyester comprises about 30 weight percent to about 70weight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 90. The foam article of any one of Aspects 42-89, wherein thethermoplastic copolyester comprises about 40 weight percent to about 70weight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 91. The foam article of any one of Aspects 42-90, wherein thethermoplastic copolyester comprises about 50 weight percent to about 70weight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 92. The foam article of any one of Aspects 42-91, wherein thethermoplastic copolyester comprises about 40 weight percent to about 65weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 93. The foam article of any one of Aspects 42-92, wherein thethermoplastic copolyester comprises about 45 weight percent to about 65weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 94. The foam article of any one of Aspects 42-93, wherein thethermoplastic copolyester comprises about 50 weight percent to about 65weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 95. The foam article of any one of Aspects 42-94, wherein thethermoplastic copolyester comprises about 55 weight percent to about 65weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 96. The foam article of any one of Aspects 42-95, wherein thethermoplastic copolyester comprises about 40 weight percent to about 60weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 97. The foam article of any one of Aspects 42-96, wherein thethermoplastic copolyester comprises about 45 weight percent to about 60weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 98. The foam article of any one of Aspects 42-97, wherein thethermoplastic copolyester comprises about 50 weight percent to about 60weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 99. The foam article of any one of Aspects 42-98, wherein thethermoplastic copolyester comprises about 55 weight percent to about 60weight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic copolyester.Aspect 100. The foam article of any one of Aspects 1-99, furthercomprising an additional thermoplastic composition.Aspect 101. The foam article of Aspect 100, wherein the additionalthermoplastic composition comprises one or more of a thermoplasticpolyurethane, an ethylene-vinyl acetate polymer, astyrene-ethylene-butylene-styrene thermoplastic elastomer, a polyetherblock amide elastomer, a polyolefin elastomer, or a combination thereof.Aspect 102. The foam article of any one of Aspects 1-101, furthercomprising an additive.Aspect 103. The foam article of any one of Aspects 1-102, comprisingless than 5 weight percent of an additive, based on the total weight ofthe thermoplastic copolyester composition.Aspect 104. The foam article of any one of Aspects 1-103, wherein theadditive is a wax, an anti-oxidant, a UV-absorbing agent, a coloringagent, or combinations thereof.Aspect 105. The foam article of any one of Aspects 1-104, furthercomprising a filler.Aspect 106. The foam article of any one of Aspects 1-105, comprisingless than 5 weight percent of a filler, based on the total weight of thethermoplastic copolyester composition.Aspect 107. The foam article of any one of Aspects 1-106, wherein thefiller is a particulate filler.Aspect 108. The foam article of any one of Aspects 1-107, wherein thefiller is a carbonaceous filler.Aspect 109. The foam article of any one of Aspects 1-108, wherein thecarbonaceous filler is carbon black, activated carbon, graphite, carbonfibers, carbon fibrils, carbon nanoparticles, or combinations thereof.Aspect 110. The foam article of any one of Aspects 1-109, wherein thecarbonaceous filler is chemically-modified.Aspect 111. The foam article of any one of Aspects 1-110, wherein thefiller is an inorganic filler.Aspect 112. The foam article of any one of Aspects 1-111, wherein theinorganic filler is an oxide, a hydroxide, a salt, a silicate, a metal,or combinations thereof.Aspect 113. The foam article of any one of Aspects 1-112, wherein theinorganic filler comprises glass spheres, glass fibers, glass hollowspheres, glass flakes, MgO, SiO₂, Sb₂O₃, Al₂O₃, ZnO, talc, mica, kaolin,wollastonite, or combinations thereof.Aspect 114. The foam article of any one of Aspects 1-113, wherein thethermoplastic copolyester has a maximum load of about 10 N to about 100N when determined using a cyclic tensile test as described herein.Aspect 115. The foam article of any one of Aspects 1-114, wherein thethermoplastic copolyester has a maximum load of about 15 N to about 50 Nwhen determined using a cyclic tensile test as described herein.Aspect 116. The foam article of any one of Aspects 1-115, wherein thethermoplastic copolyester has a maximum load of about 20 N to about 40 Nwhen determined using a cyclic tensile test as described herein.Aspect 117. The foam article of any one of Aspects 1-116, wherein thethermoplastic copolyester has tensile modulus of about 2 MPa to 20 MPawhen determined using a cyclic tensile test as described herein.Aspect 118. The foam article of any one of Aspects 1-117, wherein thethermoplastic copolyester has a zero shear viscosity of about 10 toabout 10,000 Pa·s.Aspect 119. The foam article of any one of Aspects 1-118, wherein thethermoplastic copolyester has a zero shear viscosity of about 100 toabout 7,000 Pa·s.Aspect 120. The foam article of any one of Aspects 1-119, wherein thethermoplastic copolyester has a zero shear viscosity of about 1,000 toabout 5,000 Pa·s.Aspect 121. The foam article of any one of Aspects 1-120, wherein thethermoplastic copolyester has a tensile strength of greater than orequal to about 30 kg/cm when determined using a cyclic tensile test asdescribed herein.Aspect 122. The foam article of any one of Aspects 1-121, wherein thefirst thermoplastic composition of the first foam further comprises oneor more dyes or pigments.Aspect 123. The foam article of Aspects 1-122, wherein the firstthermoplastic composition of the first foam comprises 5 weight percentor less, 4 weight percent or less, 3 weight percent or less, 2 weightpercent or less, or 1 weight percent or less of dyes or pigments.Aspect 124. The foam article of any one of Aspects 1-121, wherein thefirst thermoplastic composition of the first foam is substantially freeof dyes or pigments.Aspect 125. The foam article of any one of Aspects 1-124, wherein thefirst foam comprises a thermoplastic multicellular foam having an opencell foam microstructure, an average cell size of from about 50micrometers to about 500 micrometers, and a specific gravity of about0.15 to about 0.25;wherein the first foam compositionally comprises a first thermoplasticcomposition comprising one or more copolyesters; andwherein the first thermoplastic composition of the first foam is free oressentially free of nucleating agents, or is free or essentially free offillers, or is free or essentially free of both nucleating agents andfillers.Aspect 126. The foam article of any one of Aspects 1-124, wherein thefirst foam comprises a thermoplastic multicellular foam having an opencell foam microstructure, an average cell size of from about 50micrometers to about 500 micrometers, and a specific gravity of about0.15 to about 0.25;wherein the first foam compositionally comprises a first thermoplasticcomposition comprising one or more copolyesters;wherein the first foam is the physically foamed product of asingle-phase solution of a supercritical fluid and the firstthermoplastic composition in a molten state; andwherein the first thermoplastic composition of the first foam is free oressentially free of nucleating agents, or is free or essentially free offillers, or is free or essentially free of both nucleating agents andfillers.Aspect 127. The foam article of Aspects 125-126, wherein the foam isproduced by the method comprising:forming a single-phase solution of the first thermoplastic compositioncomprising the one or more thermoplastic copolyesters and thesupercritical fluid, wherein the first thermoplastic composition ismolten in the single-phase solution;injecting the single-phase solution into a mold cavity, the single-phasesolution having an injection temperature during the injecting;reducing pressure in the mold cavity and foaming the molten firstthermoplastic composition, the single-phase solution having a foamingtemperature during the foaming, thereby forming a first foam, whereinthe first foam is a thermoplastic multicellular foam having an open cellfoam microstructure;solidifying the first foam; andremoving the solidified first foam from the mold cavity, forming thecushioning element.Aspect 128. The foam article of any one of Aspects 125-127, wherein thesupercritical fluid comprises supercritical carbon dioxide orsupercritical nitrogen.Aspect 129. The foam article of any one of Aspects 125-128, wherein thesupercritical fluid is present in the single-phase solution in an amountof about 1 percent to about 3 percent by weight based on upon a totalweight of the single-phase solution.Aspect 130. The foam article of any one of Aspects 125-129, wherein thefoaming temperature is from about the melting temperature of thethermoplastic copolyester as determined by dynamic scanning calorimetryto about 50 degrees C. above the tail temperature of the thermoplasticcopolyester as determined by dynamic scanning calorimetry.Aspect 131. The foam article of any one of Aspects 1-130, wherein thelayer comprises a polymeric film comprising the second thermoplasticcomposition.Aspect 132. The foam article of any one of Aspects 1-131, wherein thepolymeric film comprises a multi-layer film.Aspect 133. The foam article of any one of Aspects 1-132, wherein thesecond thermoplastic composition comprises one or more thermoplasticcopolyester compositions, including a thermoplastic copolyestercomposition according to any one of Aspects 0-0.Aspect 134. The foam article of any one of Aspects 1-133, wherein thesecond thermoplastic composition comprises one or more thermoplasticpolyurethanes (TPUs).Aspect 135. The foam article of any one of Aspects 1-134, wherein thelayer is integral with the foam component.Aspect 136. The foam article of any one of Aspects 1-135, wherein thelayer is a separate component that is operably coupled with the foamcomponent.Aspect 137. The foam article of any one of Aspects 1-136, wherein thesecond thermoplastic elastomer includes a thermoplastic copolyesterelastomer, optionally wherein the thermoplastic copolyester elastomer isa thermoplastic copolyetherester elastomer.Aspect 138. The foam article of any one of Aspects 1-137, wherein thesecond thermoplastic elastomer includes a thermoplastic polyetherelastomer, optionally wherein the thermoplastic polyether elastomer is athermoplastic copolyether elastomer, optionally wherein thethermoplastic copolyether elastomer is a thermoplastic copolyetheresterelastomer or is a thermoplastic copolyetheramide elastomer.Aspect 139. The foam article of any one of Aspects 1-138, wherein thesecond thermoplastic elastomer includes a thermoplastic polystyreneelastomer, optionally wherein the thermoplastic polystyrene elastomer isa thermoplastic styrene block copolymer elastomer.Aspect 140. The foam article of any one of Aspects 1-139, wherein thethermoplastic polystyrene elastomer is a thermoplastic styrene-dienecopolymer elastomer, optionally wherein the thermoplastic styrene-dienecopolymer elastomer is a thermoplastic styrene-butadiene copolymerelastomer.Aspect 141. The foam article of any one of Aspects 1-140, wherein thesecond thermoplastic composition comprises (i) a thermoplasticpolyurethane elastomer and (ii) ethylene-vinyl acetate (EVA) copolymer,a styrene-butadiene copolymer, an ethylene-vinyl alcohol copolymer, orany combination thereof.Aspect 142. The foam article of any one of Aspects 1-141, wherein thesecond thermoplastic composition comprises a thermoplastic polyurethaneelastomer and an ethylene-vinyl alcohol copolymer.Aspect 143. The foam article of any one of Aspects 1-142, wherein thesecond thermoplastic composition comprises a second thermoplasticcopolyester elastomer.Aspect 144. The foam article of any one of Aspects 1-143, wherein thelayer has an average thickness of from about 0.01 millimeter to about 3millimeter, or from about 0.03 millimeter to about 2 millimeter, or fromabout 0.1 millimeter to about 1 millimeter.Aspect 145. The foam article of any one of Aspects 1-144, wherein thefoam article has a water uptake capacity at 5 minutes of less than 5percent, or less than 4 percent, or less than 3 percent or less than 2percent, when measured according to the Water Uptake Test Protocol.Aspect 146. The foam article of any one of Aspects 1-145, wherein thefoam article has a water uptake capacity at 5 minutes of less than 5percent, or less than 4 percent, or less than 3 percent or less than 2percent, when measured according to the Water Uptake Test Protocol.Aspect 147. The foam article of any one of Aspects 1-146, wherein thefoam article has a water uptake capacity at 5 minutes that is at least 5percentage points less, or at least 10 percentage points less, or atleast 15 percentage points less, or at least 20 percentage points less,or at least 25 percentage points less, or at least 30 percentage pointsless, than a water uptake capacity at 5 minutes for an equivalent foamarticle that does not have the polymeric layer on the exterior surface,when measured according to the Water Uptake Test Protocol.Aspect 148. The foam article of any one of Aspects 1-147, wherein thefoam article has a water uptake capacity at 5 minutes that is at least20 percent, or at least 30 percent, or at least 50 percent less than awater uptake capacity at 5 minutes for an equivalent foam article thatdoes not have the polymeric layer on the exterior surface, when measuredaccording to the Water Uptake Test Protocol.Aspect 149. The foam article of any one of Aspects 1-148, wherein thefoam article has a ply adhesion strength between the polymeric layer andthe foam component that is greater than 2.5 kg force/centimeter orgreater than 3.0 kg force/centimeter, when determined using the PlyAdhesion Test method described herein.Aspect 150. The foam article of any one of Aspects 1-149, wherein thefoam article has an average hand pull test result between the polymericlayer and the foam component that is greater than or equal to 2.0, orgreater than or equal to 2.5, or greater than or equal to 3.0, orgreater than or equal to 3.5, or greater than or equal to 4.0, orgreater than or equal to 4.5, when determined according to the Hand PullTest method described herein.Aspect 151. The foam article of any one of Aspects 1-150, wherein thelayer has an Akron abrasion of less than 0.50 cubic centimeters lost,optionally less than 0.40 cubic centimeters lost, less than 0.30 cubiccentimeters lost, less than 0.20 cubic centimeters lost, or less than0.10 cubic centimeters lost as determined using the Akron Abrasion Test.Aspect 152. The foam article of any one of Aspects 1-151, wherein thelayer has an Akron abrasion of less than 500 milligrams lost, optionallyless than 400 milligrams lost, less than 300 milligrams lost, less than200 milligrams lost, or less than 100 milligrams lost as determinedusing the Akron Abrasion Test.Aspect 153. The foam article of any one of Aspects 1-152, wherein thelayer has a DIN abrasion of less than 0.30 cubic centimeters lost,optionally less than 0.20 cubic centimeters lost, less than 0.10 cubiccentimeters lost, less than 0.05 cubic centimeters lost, or less than0.03 cubic centimeters lost as determined using the DIN Abrasion Test.Aspect 154. The foam article of any one of Aspects 1-153, wherein thelayer has a DIN abrasion of less than 300 milligrams lost, optionallyless than 250 milligrams lost, optionally less than 200 milligrams lost,optionally less than 150 milligrams lost, optionally less than 100milligrams lost, optionally less than 80 milligrams lost, optionallyless than 50 milligrams lost, or optionally less than 30 milligrams asdetermined using the DIN Abrasion Test.Aspect 155. The foam article of any one of Aspects 1-154, wherein thelayer has a dry dynamic coefficient of friction (COF) on a dry surfaceof greater than 0.5, optionally of greater than 0.7, greater than 0.8,greater than 0.9, greater than 1.0, as determined using the Dry OutsoleCoefficient of Friction Test.Aspect 156. The foam article of any one of Aspects 1-155, wherein thelayer has a wet dynamic COF of greater than 0.25, optionally of greaterthan 0.30, greater than 0.35, greater than 0.40, or greater than 0.50,as determined using the Wet Outsole Coefficient of Friction Test.Aspect 157. The foam article of any one of Aspects 1-156, wherein thefoamed first thermoplastic composition further comprises an additionalthermoplastic composition.Aspect 158. The foam article of any one of Aspects 1-157, wherein theadditional thermoplastic composition comprises one or more of athermoplastic polyurethane, an ethylene-vinyl acetate, a thermoplasticstyrene-ethylene-butylene-styrene block copolymer, a polyether blockamide, a polyolefin elastomer, or a combination thereof.Aspect 159. The foam article of any one of Aspects 1-158, wherein thefoamed first thermoplastic composition further comprises an additive.Aspect 160. The foam article of any one of Aspects 1-159, wherein theadditive is present in an amount from about 0.1 weight percent to about10 weight percent based on the total weight of the foamed firstthermoplastic composition.Aspect 161. The foam article of any one of Aspects 1-160, wherein theadditive is a wax, an anti-oxidant, a UV-absorbing agent, a coloringagent, or combinations thereof.Aspect 162. The foam article of any one of Aspects 1-161, wherein thefoamed first thermoplastic composition further comprises a filler.Aspect 163. The foam article of any one of Aspects 1-162, wherein thefiller is present in an amount from about 0.05 weight percent to about20 weight percent based on the total weight of the foamed firstthermoplastic composition.Aspect 164. The foam article of any one of Aspects 1-163, wherein thefiller is present in an amount from about 0.1 weight percent to about 10weight percent based on the total weight of the foamed firstthermoplastic composition.Aspect 165. The foam article of any one of Aspects 1-164, wherein thefiller is a particulate filler.Aspect 166. The foam article of any one of Aspects 1-165, wherein thefiller is a carbonaceous filler.Aspect 167. The foam article of any one of Aspects 1-166, wherein thecarbonaceous filler is carbon black, activated carbon, graphite, carbonfibers, carbon fibrils, carbon nanoparticles, or combinations thereof.Aspect 168. The foam article of any one of Aspects 1-167, wherein thecarbonaceous filler is chemically-modified.Aspect 169. The foam article of any one of Aspects 1-168, wherein thefiller is an inorganic filler.Aspect 170. The foam article of any one of Aspects 1-169, wherein theinorganic filler is an oxide, a hydroxide, a salt, a silicate, a metal,or combinations thereof.Aspect 171. The foam article of any one of Aspects 1-170, wherein theinorganic filler comprises glass spheres, glass fibers, glass hollowspheres, glass flakes, MgO, SiO₂, Sb₂O₃, Al₂O₃, ZnO, talc, mica, kaolin,wollastonite, or combinations thereof.Aspect 172. The foam article of any one of Aspects 1-171, wherein thefoam article has a maximum load of about 100 N to about 4000 N whendetermined using the Cyclic Tensile test as described herein.Aspect 173. The foam article of any one of Aspects 1-172, wherein thefirst thermoplastic composition has a maximum load of about 10 N toabout 100 N when determined using the Cyclic Tensile test as describedherein.Aspect 174. The foam article of any one of Aspects 1-173, wherein thefirst thermoplastic composition has a maximum load of about 15 N toabout 50 N when determined using the Cyclic Tensile test as describedherein.Aspect 175. The foam article of any one of Aspects 1-174, wherein thefirst thermoplastic composition has a maximum load of about 20 N toabout 40 N when determined using the Cyclic Tensile test as describedherein.Aspect 176. The foam article of any one of Aspects 1-175, wherein thefoam article has an energy efficiency of greater than or equal to about50 percent when determined using the Cyclic Compression test asdescribed herein.Aspect 177. The foam article of any one of Aspects 1-176, wherein thefoam article has an energy efficiency of greater than or equal to about60 percent when determined using the Cyclic Compression test asdescribed herein.Aspect 178. The foam article of any one of Aspects 1-177, wherein thefoam article has an energy efficiency of greater than or equal to about70 percent when determined using the Cyclic Compression test asdescribed herein.Aspect 179. The foam article of any one of Aspects 1-178, wherein thefoam article has an energy efficiency of about 50 percent to about 97percent when determined using the Cyclic Compression test as describedherein.Aspect 180. The foam article of any one of Aspects 1-179, wherein thefoam article has an energy return of about 400 mJ to 1000 mJ whendetermined using the Cyclic Compression test as described herein.Aspect 181. The foam article of any one of Aspects 1-180, wherein thefoam article has an energy return of about 600 mJ to 800 mJ whendetermined using the Cyclic Compression test as described herein.Aspect 182. The foam article of any one of Aspects 1-181, wherein thefoam article has a split tear value of greater than or equal to about1.5 kg/cm when determined using a split tear test as described herein.Aspect 183. The foam article of any one of Aspects 1-182, wherein thefoam article has a split tear value of greater than or equal to about2.0 kg/cm when determined using a split tear test as described herein.Aspect 184. The foam article of any one of Aspects 1-183, wherein thefoam article has a split tear value of greater than or equal to about2.5 kg/cm when determined using a split tear test as described herein.Aspect 185. The foam article of any one of Aspects 1-184, wherein thefoam article has a specific gravity of less than or equal to 0.9.Aspect 186. The foam article of any one of Aspects 1-185, wherein thefoam article has a specific gravity of about 0.1 to about 0.35.Aspect 187. The foam article of any one of Aspects 1-186, wherein thefoam article has a specific gravity of about 0.12 to about 0.20.Aspect 188. The foam article of any one of Aspects 1-187, wherein thefoam article has a stiffness of about 200 kPa to about 1000 kPa, for acylindrical sample having a diameter of about 45 millimeters asdetermined using the Cyclic Compression Test.Aspect 189. The foam article of any one of Aspects 1-188, wherein thefoam article has a stiffness of about 300 kPa to about 900 kPa for acylindrical sample having a diameter of about 45 millimeters asdetermined using the Cyclic Compression Test.Aspect 190. The foam article of any one of Aspects 1-189, wherein thefoam article has an Asker C durometer hardness of from about 30 to about50, or from about 30 to about 45, or from about 35 to about 45 or fromabout 30 to about 40, as determined using the Durometer Hardness Test.Aspect 191. The foam article of any one of Aspects 1-190, wherein thefoam article has a change in displacement at max loading of about 1 mmto about 5 mm when measured on foam slabs having a thickness of about 1cm, wherein the foam slabs are compressed for about 5000 cycles ofcompression from 0 N to 300 N and back to 0 N per cycle, using a 45 mmdiameter cylindrical tupp as the compression head.Aspect 192. The foam article of any one of Aspects 1-191, wherein thefoam article has a change in displacement at max loading of about 2 mmto about 4 mm when measured on foam slabs having a thickness of about 1cm, wherein the foam slabs are compressed for about 5000 cycles ofcompression from 0 N to 300 N and back to 0 N per cycle, using a 45 mmdiameter cylindrical tupp as the compression head.Aspect 193. A method for making a foam article, the method comprising:forming a mixture of molten first thermoplastic composition and ablowing agent, wherein the first thermoplastic composition comprises athermoplastic copolyester composition;injecting the mixture into a mold cavity;foaming the molten first thermoplastic composition thereby forming afoam article having a microcellular foam structure;removing the foam article from the mold cavity; anddisposing a layer comprising a second thermoplastic composition on anexterior surface of the foam article.Aspect 194. The method of Aspect 193, wherein the first thermoplasticcomposition comprises a thermoplastic copolyester composition accordingto any one of Aspects 1-192.Aspect 195. The method of Aspects 193-194, wherein the secondthermoplastic composition comprises one or more thermoplasticcopolyester compositions, including a thermoplastic copolyestercomposition according to any one of Aspects 9-99.Aspect 196. The method of any one of Aspects 193-195, wherein the secondthermoplastic composition comprises one or more thermoplasticpolyurethanes (TPUs).Aspect 197. The method of any one of Aspects 193-196, further comprisingdecreasing a temperature of the molten first thermoplastic compositionduring the foaming step.Aspect 198. The method of any one of Aspects 193-197, further comprisinga step of removing the foam article from the mold cavity following thedisposing step.Aspect 199. The method of any one of Aspects 193-198, further comprisinga step of removing the foam article from the mold cavity before thedisposing step.Aspect 200. The method of any one of Aspects 193-199, wherein disposingthe layer of second thermoplastic composition on an exterior surface ofthe foam article comprises placing the second thermoplastic compositionin the mold cavity prior to injecting the mixture, forming the layer inthe mold, and foaming the molten first thermoplastic composition incontact with the layer.Aspect 201. The method of any one of Aspects 193-200, wherein disposingthe layer of second thermoplastic composition on an exterior surface ofthe foam article comprises placing a film comprising the secondthermoplastic composition in the mold cavity prior to injecting themixture, and foaming the molten first thermoplastic composition incontact with the film.Aspect 202. The method of any one of Aspects 193-201, wherein disposingthe layer of second thermoplastic composition on an exterior surface ofthe foam article comprises thermally laminating a film to the exteriorsurface of the foam article, wherein the film comprises the secondthermoplastic composition.Aspect 203. The method of any one of Aspects 193-202, wherein thermallylaminating comprises increasing the temperature of the film, theexterior surface of the foam article, or both, to a temperature abovethe softening point of the respective material, and then contacting thefilm with the exterior surface of the foam article.Aspect 204. The method of any one of Aspects 193-203, wherein disposingthe layer of second thermoplastic composition on an exterior surface ofthe foam article comprises adhesively laminating a film to the exteriorsurface of the foam article, wherein the film comprises the secondthermoplastic composition.Aspect 205. The method of any one of Aspects 193-204, wherein disposingthe layer comprising the second thermoplastic composition on an exteriorsurface of the foam article comprises applying a coating comprising thesecond thermoplastic composition on an exterior surface of the foamarticle.Aspect 206. The method of any one of Aspects 193-205, wherein applying acoating comprises applying a liquid coating material comprising thesecond thermoplastic composition or a precursor of the secondthermoplastic composition onto an exterior surface of the foam article,and then drying, curing, or drying and curing the liquid coatingmaterial on the exterior surface of the foam article.Aspect 207. The method of any one of Aspects 193-206, wherein applyingthe liquid coating material comprises spraying, dip coating,tumble-coating, brushing, or a combination thereof.Aspect 208. The method of any one of Aspects 193-207, wherein applying acoating comprises applying a powder coating material comprising thesecond thermoplastic composition or a precursor of the secondthermoplastic composition onto an exterior surface of the foam article.Aspect 209. The method of any one of Aspects 193-208, wherein applyingthe powder coating material comprises spraying, powder coating,electro-static coating, tumble-coating, or a combination thereof.Aspect 210. The method of any one of Aspects 193-209, wherein applyingthe powder coating material comprises applying an adhesive to affix thepowder coating material to the foam article.Aspect 211. The method of any one of Aspects 193-210, wherein applyingthe coating further comprises heating the powder coating material,melting at least a portion of the powder coating material on the foamarticle.Aspect 212. The method of any one of Aspects 193-211, wherein applyingthe coating further comprises applying a solvent to the powder coatingmaterial on the foam article.Aspect 213. The method of any one of Aspects 193-212, wherein disposingthe layer of second thermoplastic composition on an exterior surface ofthe foam article comprises coupling a rand or foxing tape comprising thesecond thermoplastic composition with the exterior surface of the foamarticle.Aspect 214. The method of any one of Aspects 193-213, wherein theblowing agent is a physical blowing agent.Aspect 215. The method of any one of Aspects 193-214, wherein thephysical blowing agent is a supercritical fluid.Aspect 216. The method of any one of Aspects 193-215, wherein thesupercritical fluid comprises nitrogen, or a supercritical fluidthereof.Aspect 217. The method of any one of Aspects 193-216, wherein thesupercritical fluid consists essentially of nitrogen, or a supercriticalfluid thereof.Aspect 218. The method of any one of Aspects 193-217, wherein thesupercritical fluid further comprises carbon dioxide, or a supercriticalfluid thereof.Aspect 219. The method of any one of Aspects 193-218, wherein the carbondioxide is present in an amount of about 0.1 percent to about 5 percentby weight based on upon a total weight of the mixture.Aspect 220. The method of any one of Aspects 193-219, wherein the carbondioxide is present in an amount of about 1 percent to about 3 percent byweight based on upon a total weight of the mixture.Aspect 221. The method of any one of Aspects 193-220, wherein thenitrogen is present in an amount of about 0.1 percent to about 5 percentby weight based on upon a total weight of the mixture.Aspect 222. The method of any one of Aspects 193-221, wherein thenitrogen is present in an amount of about 1 percent to about 3 percentby weight based on upon a total weight of the mixture.Aspect 223. The method of any one of Aspects 193-222, wherein theforming the mixture of the molten first thermoplastic composition andthe physical blowing agent comprises adding a supercritical fluid to themolten first thermoplastic composition and forming a single phasesolution of the supercritical fluid dissolved in the molten firstthermoplastic composition.Aspect 224. The method of any one of Aspects 193-223, wherein theforming the mixture of the molten first thermoplastic composition andthe physical blowing agent comprises infusing solid first thermoplasticcomposition with a supercritical fluid to form an infused resin, andmelting the infused resin to form a single phase solution of thesupercritical fluid and the molten first polymeric mixture.Aspect 225. The method of any one of Aspects 193-224, wherein theinjecting the mixture into the mold cavity comprises injecting themixture into a pressurized mold cavity at a first pressure greater thanatmospheric pressure; and the foaming the molten first thermoplasticcomposition comprises decreasing the first pressure to a second pressureand initiating formation of gas bubbles by the physical blowing agent,thereby foaming the molten first thermoplastic composition whiledecreasing the temperature of the molten first thermoplasticcomposition, and forming the microcellular foam article.Aspect 226. The method of any one of Aspects 193-225, wherein the secondpressure is atmospheric pressure; and wherein decreasing the firstpressure to the second pressure comprises venting the pressurized moldcavity to atmospheric pressure.Aspect 227. The method of any one of Aspects 193-226, wherein the secondpressure is atmospheric pressure; and wherein decreasing the firstpressure to the second pressure comprises a controlled rate of pressuredecrease until the mold cavity has a pressure essentially equal toatmospheric pressure.Aspect 228. The method of any one of Aspects 193-227, wherein the secondpressure is atmospheric pressure; and wherein decreasing the firstpressure to a second pressure comprises decreasing the pressure in aplurality of incremental steps until the mold cavity has a pressureessentially equal to atmospheric pressure.Aspect 229. The method of any one of Aspects 193-228, wherein thedecreasing the first pressure to the second pressure comprises applyinga gas counter pressure from about 100 psi to about 3,000 psi.Aspect 230. The method of any one of Aspects 193-229, wherein theblowing agent is a chemical blowing agent.Aspect 231. The method of any one of Aspects 193-230, wherein thechemical blowing agent is present in an amount from about 0.05 weightpercent to about 25 weight percent based on the total weight of thefirst polymeric mixture.Aspect 232. The method of any one of Aspects 193-231, wherein thechemical blowing agent is present in an amount from about 0.1 weightpercent to about 10 weight percent based on the total weight of thefirst polymeric mixture.Aspect 233. The method of any one of Aspects 193-232, wherein thechemical blowing is an azo compound.Aspect 234. The method of any one of Aspects 193-233, wherein theblowing agent comprises a combination of a physical blowing agent and achemical blowing agent.Aspect 235. The method of any one of Aspects 193-234, wherein theblowing agent is substantially free of a chemical blowing agent or adecomposition product thereof.Aspect 236. The method of any one of Aspects 193-235, wherein theblowing agent is substantially free of a physical blowing agent.Aspect 237. The method of any one of Aspects 193-236 wherein the mixturehas an injection temperature; and wherein the injection temperature isfrom about the melting temperature of the thermoplastic copolyestercomposition to about 50 degrees C. above the tail temperature of thethermoplastic copolyester composition.Aspect 238. The method of any one of Aspects 193-237, wherein theinjection temperature is from about the melting temperature of thethermoplastic copolyester composition to a temperature that is above thetail temperature of the thermoplastic copolyester composition by about 0degrees C., 5 degrees C., 10 degrees C., 15 degrees C., 20 degrees C.,25 degrees C., 30 degrees C., 35 degrees C., 40 degrees C., 45 degreesC., or 50 degrees C.Aspect 239. The method of any one of Aspects 193-238, wherein thefoaming occurs at a foaming temperature; and wherein the foamingtemperature is from about the melting temperature of the thermoplasticcopolyester composition to about 50 degrees C. above the tailtemperature of the thermoplastic copolyester composition.Aspect 240. The method of any one of Aspects 193-239, wherein thefoaming temperature is from about the melting temperature of thethermoplastic copolyester composition to a temperature that is above thetail temperature of the thermoplastic copolyester composition by about 0degrees C., 5 degrees C., 10 degrees C., 15 degrees C., 20 degrees C.,25 degrees C., 30 degrees C., 35 degrees C., 40 degrees C., 45 degreesC., or 50 degrees C.Aspect 241. The method of any one of Aspects 193-240, the method furthercomprising placing a textile element in the mold cavity prior toinjecting the mixture, and foaming the molten first thermoplasticcomposition in contact with the textile element.Aspect 242. The method of any one of Aspects 192-241, wherein thetextile element comprises a woven, braided, crocheted, knitted textilecomprising one or more yarns, wherein each of the one or more yarns isformed of one or more individual fibers.Aspect 243. The method of any one of Aspects 192-242, wherein thetextile element comprises a non-woven textile comprising a plurality offibers.Aspect 244. The method of any one of Aspects 192-241, wherein the one ormore fibers or yarns comprise a thermoplastic composition comprisingpolyester, thermoplastic polyurethane, or combinations thereof.Aspect 245. The method of any one of Aspects 192-244, wherein thetextile element is a component for an upper for an article of footwear.Aspect 246. The method of any one of Aspects 192-245, wherein the foamarticle is a component of an article of footwear.Aspect 247. The method of any one of Aspects 192-246, wherein the foamarticle is a component of an article of apparel.Aspect 248. The method of any one of Aspects 192-247, wherein the foamarticle is a component of an article of sporting equipment.Aspect 249. A molding system for forming a foam article, the systemcomprising: a first barrel housing a first screw configured to receive amolten first thermoplastic composition and form a mixture of the moltenfirst thermoplastic composition comprising a thermoplastic copolyestercomposition and a blowing agent, and to adjust a position of the firstscrew in the first barrel to regulate a flowrate of the mixture out ofthe first barrel; a mold cavity configured to contain the mixture duringfoaming, mold the foamed mixture, and solidify the molded foamed mixtureinto the foam article; a first injection or extrusion device configuredto receive the mixture and extrude or inject it into the mold cavity ata first injection pressure and temperature; and a first temperaturecontrol and monitoring system configured to control the injectiontemperature or a foaming temperature at which the molten firstthermoplastic composition is foamed within the mold cavity, or both.Aspect 250. The molding system of Aspect 249, further comprising asecond barrel housing a second screw configured to receive a moltensecond thermoplastic composition, and to adjust a position of the secondscrew in the second barrel to regulate a flowrate of the secondthermoplastic composition out of the second barrel; and a secondinjection or extrusion device configured to receive the secondthermoplastic composition and extrude or inject it into the mold cavityat a second injection pressure and temperature; and a second temperaturecontrol and monitoring system configured to control the second injectiontemperature or a second molding temperature at which the molten secondthermoplastic composition is maintained within the mold cavity, or both.Aspect 251. The molding system of Aspects 249-250, wherein the firsttemperature control and monitoring system is configured to control thefirst injection temperature of the mixture or the foaming temperature ofthe molten first thermoplastic composition or both within a temperatureranging from about the melting temperature of the thermoplasticcopolyester composition to about 50 degrees C. above the tailtemperature of the thermoplastic copolyester composition.Aspect 252. The molding system of any one of Aspects 249-251, furthercomprising a gas counter pressure assembly coupled to the mold cavity,wherein the gas counter pressure assembly is configured to regulate anamount of counter pressure gas flow into the mold cavity before, duringor after extruding or injecting the mixture into the mold cavity, orduring foaming of the molten first thermoplastic composition in the moldcavity.Aspect 253. The molding system of any one of Aspects 249-252, furthercomprising a mold cavity venting system configured to regulate a rate ofpressure loss due to gas flow out of the mold cavity.Aspect 254. The molding system of any one of Aspects 249-253, whereinthe system further comprises a runner system in fluid communication withthe injection or extrusion device and the mold cavity.Aspect 255. The molding system of any one of Aspects 249-254, whereinthe runner system is configured to control a temperature of the mixtureas it flows through the runner.Aspect 256. The molding system of any one of Aspects 249-255, whereinthe runner system is configured to heat the mixture as it flows throughthe runner.Aspect 257. The molding system of any one of Aspects 249-256, whereinthe system includes a pressure control assembly configured to control apressure of the mixture as it enters the mold cavity.Aspect 258. A method for operation of a molding system for forming afoam article, the method comprising: forming a mixture of a molten firstthermoplastic composition comprising a thermoplastic copolyestercomposition and a blowing agent in a first barrel housing a first screw;adjusting a position of the first screw in the first barrel to regulatea flowrate of the mixture out of the first barrel; flowing the mixturefrom the first barrel into a mold cavity; extruding or injecting themixture into the mold cavity at a first injection pressure and a firstinjection pressure; foaming the molten first thermoplastic compositionin the mold cavity at a foaming temperature, thereby forming a foamedmolten first thermoplastic composition; and solidifying the foamedmolten first thermoplastic composition in the mold cavity, therebyforming a foam article having a multicellular foam structure.Aspect 259. The method of operation of Aspect 258, wherein the methodfurther comprises providing a molten second thermoplastic composition ina second barrel housing a second screw; adjusting a position of thesecond screw in the second barrel to regulate a flowrate of the mixtureout of the second barrel; flowing the molten second thermoplasticcomposition from the second barrel into the mold cavity; extruding orinjecting the second thermoplastic composition into the mold cavity at asecond injection pressure and a second injection pressure; andsolidifying the molten second thermoplastic composition in the moldcavity, thereby forming a polymeric layer.Aspect 260. The method of operation of any one of Aspects 258-259,wherein the method further comprises monitoring and controlling thefirst injection temperature of the mixture or the first foamingtemperature of the molten first thermoplastic composition or both withina temperature ranging from about the melting temperature of thethermoplastic copolyester composition to about 50 degrees C. above thetail temperature of the thermoplastic copolyester composition.Aspect 261. The method of operation of any one of Aspects 258-260,further comprising regulating an amount of counter pressure gas flowinginto the mold cavity before, during or after extruding or injecting themixture into the mold cavity, or during foaming of the molten firstthermoplastic composition in the mold cavity.Aspect 262. The method of operation of any one of Aspects 258-261,further comprising releasing gas from the mold cavity at a controlledrate during the extruding or injecting or during the foaming.Aspect 263. The method of operation of any one of Aspects 258-262,further comprising controlling a temperature of the mixture as it flowsthrough a runner into the mold cavity.Aspect 264. The method of operation of any one of Aspects 258-263,further controlling the first injection pressure of the mixture as itenters the mold cavity.Aspect 265. An article comprising the foam article of any one of Aspects1-192.Aspect 266. An article comprising the foam article of made by the methodof any one of Aspects 193-248.Aspect 267. The article of Aspects 265-266, wherein the article is anarticle of footwear.Aspect 268. The article of any one of Aspects 265-267, wherein the foamarticle is a cushioning element in the article of footwear.Aspect 269. The article of any one of Aspects 265-268, wherein thecushioning element is a component of a sole structure in the article offootwear.Aspect 270. The article of any one of Aspects 265-269, wherein the foamarticle is a component of a sole structure in the article of footwear.Aspect 271. The article of any one of Aspects 265-270, wherein the solestructure has a first side that is configured to be ground-facing whenthe sole structure is a component of an article of footwear, a secondside opposed to the first side, and a sidewall extending at leastpartially between the first side and the second side; wherein the layercomprising the second thermoplastic composition is disposed on one ormore of the first side, the second side, or the sidewall.Aspect 272. The article of any one of Aspects 265-271, wherein the solestructure is a midsole.Aspect 273. The article of any one of Aspects 265-272, wherein the solestructure is a plate.Aspect 274. The article of any one of Aspects 265-273, wherein the solestructure is a chassis.Aspect 275. The article of any one of Aspects 265-274, wherein the solestructure is a bladder.Aspect 276. The article of any one of Aspects 265-275, wherein the solestructure is a bladder, and the foam article is disposed on an exteriorsurface of the bladder.Aspect 277. The article of any one of Aspects 265-276, wherein the solestructure is a heel cushion.Aspect 278. The article of any one of Aspects 265-277, wherein the solestructure comprises a shell component that at least partially enclosesthe foam article, wherein the shell component comprises the layercomprising the second thermoplastic composition.Aspect 279. The article of any one of Aspects 265-278, wherein the shellcomponent encloses the foam article on the first side and the sidewallof the sole structure.Aspect 280. The article of any one of Aspects 265-279, wherein the shellcomponent is attached to the upper of the article of footwear.Aspect 281. The article of any one of Aspects 265-280, wherein the solestructure further comprises an outsole component on the ground-facingside of the sole structure.Aspect 282. The article of any one of Aspects 265-281, wherein theoutsole component comprises a cured rubber.Aspect 283. The article of any one of Aspects 265-282, wherein a side ofthe foam article is bonded to an upper.Aspect 284. The article of any one of Aspects 265-283, wherein the uppercomprises a polyester yarn, a polyester fiber, a thermoplasticpolyurethane yarn, a thermoplastic polyurethane fiber, or combinationsthereof.Aspect 285. The article of any one of Aspects 265-284, wherein the sideof the foam article bonded to an upper is bonded using an adhesive.Aspect 286. The article of any one of Aspects 265-285, wherein the sideof the foam article bonded to an upper is essentially free of anadhesive at a bond interface between the side of the foam article andthe upper.Aspect 287. The article of any one of Aspects 265-286, wherein thearticle is an article of apparel.Aspect 288. The article of any one of Aspects 265-287, wherein thearticle is an article of sporting equipment.Aspect 289. A method for manufacturing an article of footwear, themethod comprising:affixing a foam article and an additional element to each other;wherein the foam article is a foam article of any one of Aspects 1-192.Aspect 290. A method for manufacturing an article of footwear, themethod comprising:affixing a foam article and an additional element to each other;wherein the foam article is a foam article made by the method one ofAspects 193-248.Aspect 291. The method of Aspects 289-290, wherein the additionalelement is a textile element, a film element, a solid element, or acombination thereof.

EXAMPLES

Now having described the aspects of the present disclosure, in general,the following Examples describe some additional aspects of the presentdisclosure. While aspects of the present disclosure are described inconnection with the following examples and the corresponding text andfigures, there is no intent to limit aspects of the present disclosureto this description. On the contrary, the intent is to cover allalternatives, modifications, and equivalents included within the spiritand scope of the present disclosure.

Materials.

HYTREL 3078 and HYTREL 4068 were obtained from DuPont (Wilmington, Del.,USA).

Processing Conditions.

Foam plaques were prepared according to the conditions shown in Table 1below:

TABLE 1 Melt Temp Mold Temp Injection Speed Fill time MPP GCP GCPMaterial (° C.) (° C.) (cc/sec) (s) (Bar) N₂ (%) (PSI) release Hytrel4068 210 54 100 2.5 175 0.5 600 End of fill Hytrel 3078 200 40 100 2.5175 0.5 000 End of fill

Foam midsoles were prepared according to the conditions shown in Table 2below:

TABLE 2 Melt Temp Mold Tamp Injection Speed Fill time Cooling MPP N₂ GCPGCP Material (° C.) (° C.) (cc/sec) (s) Time (s) (Bar) (%) (PSI) releaseHytrel 4068 210 54 100 2.5 400 175 1.22 600 End of fill Hytrel 3078 20040 100 2.5 400 175 1.5  600 End of fill

Foam plaques were prepared according to the conditions shown in Table 3below.

TABLE 3 Mold Temperature Mold relative to Temperature Mold peak relativeto tail Temperature temperature temperature (degrees (degrees (degreesFoam No. Polyester centigrade) centigrade) centigrade) Quality 1 Triel®5400 160 +5 −16 Good 2 Toyobo P- 175   0 −18 Poor 30B 3 Toyobo P- 190+15 −3 Good 30B 4 Toyobo P- 205 +30 +12 Coarse 30B 5 Toyobo P- 245 +70+52 Coarser 30B

Cross-sectional views of the foam plaques described above are shown inFIGS. 9A-9D (for Nos. 2-5 above) and FIG. 10 (for No. 1 above).

Example 1. Exemplary Data of Foam Plaques

Foam plaques were prepared as described above using HYTREL 4068.Exemplary compression data are shown in FIG. 6. The data were obtainedby a cyclic compression testing protocol on a plaque in the form of acylindrical tupp having the following dimensions: thickness—20 mm;diameter—44.86 mm. The compression data in FIG. 6 are a representativecompression curve. The data obtained from these tests are summarized inTable 4 below.

TABLE 4 Average Average Energy Modulus Stiffness Max Efficiency ReturnMaterial (kPa) (N/mm) Strain (%) (mJ) Hytrel 4068 554 80 0.377 87 397

The specific gravity for foam plaques, prepared as described hereinabove, was determined to be 0.16-0.28 for HYTREL 4068 and 0.17-0.26HYTREL 3078.

The foam plaques described in Table 3 above were subjected to energyreturn analysis as described herein. The results are shown in Table 5below.

TABLE 5 Energy Return No. Polyester (mJ) 1 Triel® 5400 2830 2 Toyobo P-2050 30B 3 Toyobo P- 2940 30B 4 Toyobo P- 3150 30B 5 Toyobo P- 2950 30B

Example 2. Exemplary Data of Foam Midsoles

Foam midsoles were prepared as described above using HYTREL 4068.Compression data were obtained by a cyclic compression testing protocolusing a footform as described above. The data obtained from these testsare summarized in Table 6 below.

TABLE 6 Average Average Max Energy Modulus Stiffness DisplacementEfficiency Return Material (kPa) (N/mm) (mm) (%) (mJ) Hytrel 4068 N/A173 11.57 74 4078

The specific gravity for foam midsoles, prepared as described hereinabove, was determined to be 0.19-0.27 for HYTREL 4068 and 0.19-0.26HYTREL 3078.

Example 3. Exemplary Hand Pull Data

A foam article was prepared comprising a first foam component and asecond s component. The first foam component was an open-cell foamformed from a first thermoplastic copolyester composition comprisingHYTREL 4068 which contained less than 1 weight percent of non-polymericmaterials. The first thermoplastic copolyester composition was injectionmolded, foamed and bonded in place to the second solid component. Thethermoplastic copolyester composition was foamed using the MUCELLprocess by forming a single-phase solution of carbon dioxide and thethermoplastic copolyester composition. The first thermoplasticcopolyester composition was injection molded and foamed onto a preformedsecond component as described herein below. The second solid componentwas prepared as a solid plaque using a second thermoplastic copolyestercomposition, i.e., a second thermoplastic composition comprising one ofthe four listed polymers shown in the table below (MP IN15074, HYTREL3078, TRIEL 5202SU, and SP9339, which are further described in Table 8).The first foam component was bonded to the second foam component, i.e.,a plaque comprising a solid second thermoplastic composition, byinjecting, foaming, and molding a single-phase solution of carbondioxide and a thermoplastic copolyester composition comprising HYTREL4068 onto the outsole plaque in an injection mold. Prior to placing theoutsole plaque into the mold, one of the following treatments was used:a) no surface preparation was conducted on the surface of the outsoleplaque onto which the foam was injected (i.e., control sample); b) theoutsole plaque surface was wiped with methyl ethyl ketone prior toinsertion into the mold; c) the outsole plaque surface was treated usinga rotating cone open air plasma treatment immediately prior to insertioninto the mold and injection of the foam composition, where the plaquesurface was held 1 cm away from the emitting head, and the plaque wasmoved passed the emitting head at a rate of about 100-200 mm/sec; or d)the outsole plaque was heated using an infrared lamp for at least 30seconds after insertion into the mold and immediately prior to injectionof the foam composition. The equipment used was a PlasmatreatOPENAIR-PLASMA System with an RD1004 head (Plasmatreat GmbH, Steinhagen,Germany).

Hand pull data were obtained using the Hand Pull Test as describedherein above. The data obtained are shown in Table 7 below. The data inTable 7 indicate that good bonding of the foam to an outsole materialcan be achieved using a direct bonding process with little if anyadditional process steps prior to foaming and molding in place the firstfoam component.

TABLE 7 Surface Prep of Outsole Polymer* Foam Plaque MP IN15074 HY3078TRIEL 5202SU SP9339 No treatment 1 2 3.5 2 MEK wipe 1 3 3 3 Plasmatreat1.5 4.5 4 3.5 IR pre-treatment 1 4.5 4 4 *Values correspond to thefollowing results in Hand Pull Test: 1—easy to peel adhesive failure;2—adhesive failure, but some resistance; 3—4.5 cohesive foam failure,varying levels of foam skin failure; 5—unable separate)

Example 4. Exemplary Data of Second Thermoplastic CompositionCharacterization—Coefficient of Friction—Polymer Samples

Sample preparation, coefficient of friction, and other test procedureswere carried out as described herein above. The coefficient of frictiondata for wood and concrete surfaces are shown in the table shown inFIGS. 11 and 12, respectively. The materials referred into FIGS. 11 and12 are further described in Table 8 below.

TABLE 8 Material Grade Polymer type Form Supplier BT 1030D CoPe TPESolid LG Desmopan 8795A TPU Foam Covestro Ellastolan b70a TPU SolidLubrizol Ellastolan SP9339 TPU Foam BASF Ellastolan SP9339 TPU SolidBASF Estane t470a-3 TPU Solid Lubrizol HPF AD1035 Ethlyenic TPE/lonomerSolid DuPont HPF AD1172 Ethlyenic TPE/lonomer Solid DuPont Hytrel 3078CoPe TPE Solid DuPont Hytrel 3078 CoPe TPE Foam DuPont Hytrel 3078 CoPeTPE Solid DuPont Hytrel 4068 CoPe TPE Foam DuPont Hytrel 4556 CoPe TPESolid DuPont KP3340 CoPe TPE Solid Kolon KP3347 CoPe TPE Solid KolonKurarity LA2250 Acrylic TPE Solid Kuraray Kurarity LA4285 Acrylic TPESolid Kuraray Monprene 12990 SEBS TPE Foam Teknor Apex Monprene 66070SEBS TPE Solid Teknor Apex Monprene CP28160-01 SEBS TPE Solid TeknorApex Monprene IN15056 SEBS TPE Solid Teknor Apex Monprene IN15074 SEBSTPE Solid Teknor Apex Monprene IN15074 SEBS TPE Foam Teknor ApexMonprene SP16074H SEBS TPE Solid Teknor Apex Monprene SP16975 SEBS TPESolid Teknor Apex Santoprene 123-40 TPV: EPDM/PP Solid-Herringbone ExxonSantoprene 201-64 TPV: EPDM/PP Solid-Herringbone Exxon Santoprene 103-50TPV: EPDM/PP Solid-Herringbone Exxon Sarlink 3160 TPV: EPDM/PP SolidTeknor Apex Sarlink 6755B TPV: EPDM/PP Solid Teknor Apex Sarlink 6755NTPV: EPDM/PP Solid Teknor Apex Septon blends w/PP (16-011-4) SEBS/PPcompound Solid Kuraray Septon blends w/PP (16-051-1) SEBS/PP compoundSolid Kuraray Septon blends w/PP (16-078-2) SEBS/PP compound SolidKuraray Surlyn 8150 Ethlyenic TPE/ lonomer Solid DuPont Surlyn 8320Ethlyenic TPE/ lonomer Solid DuPont Surlyn 9320 Ethlyenic TPE/ lonomerSolid DuPont Topgreen RH 1502-2 CoPe TPE Solid FENC Topgreen RH 1601-7CoPe TPE Solid FENC TPSiV-50A TPV: Silicone/Hytrel Solid DuPontTPSiV-60A TPV: Silicone/Hytrel Solid DuPont Triel 52025P CoPe TPE SolidSamYang Triel 52025P CoPe TPE Foam SamYang Triel 5300 CoPe TPE SolidSamYang Triel 5401A CoPe TPE Solid SamYang Triel SY 5280 CoPe TPE SolidSamYang Tuftec P1500 SEBS TPE Solid Asahi Tuftec P5051 SEBS TPE SolidAsahi Zeotherm 100-70B TPV: ACM/PA Solid Zeon Chemical Zeotherm 100-80BTPV: ACM/PA Solid Zeon Chemical Zeotherm 110-70B TPV: ACM/PA Solid ZeonChemical Zeotherm 130-90B TPV: ACM/PA Solid Zeon Chemical

Table 8, the abbreviations used therein have the following meaning:“TPU” means “Thermoplastic Polyurethane”; CoPe TPE means “CopolyesterThermoplastic Elastomer”; “Ethylenic TPE/Ionomer” means “EthylenicThermoplastic Elastomer/Ionomer”; “Acrylic TPE” means “AcrylicThermoplastic Elastomer”; “SEBS TPE” means“Styrene-Ethylene-Butadiene-Styrene Thermoplastic Elastomer”;“TPV/EPDM/PP” means “Styrene-Ethylene-Butadiene-Styrene ThermoplasticElastomer Thermoplastic Vulcanizate of Ethylene Propylene Diene MonomerRubber and Thermoplastic Polypropylene”; “TPV: Silicone/Hytrel” means“Thermoplastic Vulcanizate of Silicone Rubber and ThermoplasticCopolyester”; and “TPV: ACM/PA” means “Thermoplastic Vulcanizate ofAcryl Acrylate Copolymer Rubber and Thermoplastic Polyamide”.

Example 5. Exemplary Data of Second Thermoplastic CompositionCharacterization—Coefficient of Friction—Blown Outsole Samples

Sample preparation, coefficient of friction, and other test procedureswere carried out as described herein above. The coefficient of frictiondata for concrete surfaces are shown in the table shown in FIG. 13. Thematerials referred into FIG. 13 are further described in Table 8 above.

Example 6. Exemplary Data of Second Thermoplastic CompositionCharacterization—Specific Gravity—Blown Outsole Samples

Sample preparation and specific gravity test procedures were carried outas described herein above. The coefficient of friction data for concretesurfaces are shown in the table shown in FIG. 14. The samplesapproximated ‘blown’ rubber via physically foamed thermoplastic resinsusing added compressed gas or SCF. The materials referred into FIG. 14are further described in Table 8 above.

It should be emphasized that the above-described aspects of the presentdisclosure are merely possible examples of implementations, and are setforth only for a clear understanding of the principles of thedisclosure. Many variations and modifications may be made to theabove-described aspects of the disclosure without departingsubstantially from the spirit and principles of the disclosure. All suchmodifications and variations are intended to be included herein withinthe scope of this disclosure.

What is claimed:
 1. A cushioning element for an article of footwear, thecushioning element comprising: a first foam component having an exteriorsurface, the foam component comprising a foamed first thermoplasticcomposition comprising a first thermoplastic copolyester elastomerhaving a multicellular foam structure; and a polymeric layer comprisinga second thermoplastic composition comprising a second thermoplasticelastomer, and the polymeric layer is disposed on at least a portion ofthe exterior surface of the first foam component; wherein the firstthermoplastic composition is structurally different than the secondthermoplastic composition.
 2. The cushioning element of claim 1, whereinthe second thermoplastic elastomer comprises a thermoplasticpolyurethane elastomer, a thermoplastic polyurea elastomer, athermoplastic polyether elastomer, a thermoplastic polyester elastomer,a thermoplastic polyamide elastomer, a thermoplastic polystyreneelastomer, a thermoplastic polyolefin elastomer, a thermoplasticpolyimide elastomer, any copolymer thereof, or any blend thereof.
 3. Thecushioning element of claim 1, wherein the second thermoplasticcomposition comprises one or more thermoplastic polyurethanes (TPUs). 4.The cushioning element of claim 1, wherein the second thermoplasticcomposition comprises (i) a thermoplastic polyurethane elastomer and(ii) ethylene-vinyl acetate (EVA) copolymer, a styrene-butadienecopolymer, an ethylene-vinyl alcohol copolymer, or any combinationthereof.
 5. The cushioning element of claim 1, wherein the secondthermoplastic composition comprises a second thermoplastic copolyesterelastomer.
 6. The cushioning element of claim 5, wherein the firstthermoplastic copolyester elastomer comprises (a) a plurality of firstsegments, each first segment derived from a dihydroxy-terminatedpolydiol; (b) a plurality of second segments, each second segmentderived from a diol; and (c) a plurality of third segments, each thirdsegment derived from an aromatic dicarboxylic acid.
 7. The cushioningelement of claim 1, wherein the first thermoplastic copolyesterelastomer comprises, (a) a plurality of first copolyester units, eachfirst copolyester unit of the plurality comprising the first segmentderived from a dihydroxy-terminated polydiol and the third segmentderived from an aromatic dicarboxylic acid, wherein the firstcopolyester unit has a structure represented by a formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide) diol of the first segment, whereinthe poly(alkylene oxide) diol of the first segment is a poly(alkyleneoxide) diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and (b) a plurality of second copolyester units, each secondcopolyester unit of the plurality comprising the second segment derivedfrom a diol and the third segment derived from an aromatic dicarboxylicacid, wherein the second copolyester unit has a structure represented bya formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.
 8. The cushioningelement of claim 1, wherein the first foam comprises a thermoplasticmulticellular foam having an open cell foam microstructure, an averagecell size of from about 100 microns to about 1 millimeter, and aspecific gravity of about 0.05 to about 0.25; wherein the firstthermoplastic composition of the first foam is free or essentially freeof nucleating agents, or is free or essentially free of fillers, or isfree or essentially free of both nucleating agents and fillers.
 9. Thecushioning element of claim 1, wherein the polymeric layer has anaverage thickness of from about 0.01 millimeter to about 3 millimeter.10. The cushioning element of claim 1, wherein the cushioning elementhas a water uptake capacity at 5 minutes that is at least 2 percentagepoints less than a water uptake capacity at 5 minutes for an equivalentcushioning element that lacks the polymeric layer as determined usingthe Water Uptake Capacity Test method.
 11. The cushioning element ofclaim 1, wherein the cushioning element has a ply adhesion strengthbetween the polymeric layer and the foam component that is greater than2.5 kg force/centimeter when determined using the Ply Adhesion Testmethod described herein.
 12. The cushioning element of claim 1, whereinthe cushioning element has an average hand pull test result between thepolymeric layer and the foam component that is greater than or equal to2.0, when determined according to the Hand Pull Test method describedherein.
 13. The cushioning element of claim 1, wherein the cushioningelement is a midsole or a heel cushion.
 14. An article of footwearcomprising the cushioning element of claim
 1. 15. A method of making acushioning element for an article of footwear, the method comprising:forming a first foam component having an exterior surface, the foamcomponent comprising a foamed first thermoplastic composition comprisinga first thermoplastic copolyester elastomer having a multicellular foamstructure; and disposing a polymeric layer on at least a portion of theexterior surface of the first foam component, wherein the polymericlayer comprises a second thermoplastic composition comprising a secondthermoplastic elastomer; wherein the first thermoplastic composition isstructurally different than the second thermoplastic composition. 16.The method of claim 15, wherein the forming comprises injection moldingand foaming the first foam component by injection molding the firstthermoplastic composition in an injection mold, solidifying the firstthermoplastic composition to retain the multicellular foam structure,and removing the solidified first foam component from the injectionmold; and wherein the disposing comprises, after the solidifying,applying heat or vacuum or both heat and vacuum to a thermoplastic filmcomprising the second thermoplastic composition, thereby disposing andbonding the polymeric film to the exterior surface of the first foamcomponent, forming the polymeric layer on the exterior surface of thefirst foam component, and forming the cushioning element.
 17. The methodof claim 15, wherein the forming comprises injection molding and foamingthe first foam component by injection molding the first thermoplasticcomposition in an injection mold, solidifying the first thermoplasticcomposition to retain the multicellular foam structure, and removing thesolidified first foam component from the injection mold; and wherein thedisposing comprises, after the solidifying, applying the secondthermoplastic composition in liquid form to the exterior surface of thefirst foam component, and allowing the second thermoplastic compositionto solidify, thereby forming, disposing and bonding the polymeric layerto the exterior surface of the first foam component and forming thecushioning element.
 18. The method of claim 17, wherein the applying thesecond thermoplastic composition in liquid form comprises spraying,printing, or painting the second thermoplastic composition onto theexterior surface, and the allowing the second thermoplastic compositionto solidify comprises evaporating a solvent from the secondthermoplastic composition.
 19. The method of claim 15, wherein theforming and disposing comprise placing a polymeric film comprising thesecond thermoplastic composition in a mold; melting the first polymericcomposition; foaming the molten first polymeric composition; extrudingthe foamed first polymeric composition into the mold and onto an exposedsurface of the polymeric film in the mold; solidifying the foamed firstthermoplastic material, thereby bonding the exposed surface of thepolymeric film to the solidified foamed first thermoplastic material andforming the polymeric layer on the first foam component, and therebyforming the cushioning element; and removing the cushioning element fromthe mold.
 20. The method of claim 15, wherein the forming and disposingcomprise placing a polymeric film comprising the second thermoplasticcomposition in an injection mold; melting the first polymericcomposition; injecting the molten first polymeric composition into themold and onto an exposed surface of the polymeric film in the mold;foaming the molten first polymeric composition in the mold; solidifyingthe foamed first thermoplastic material, thereby bonding the exposedsurface of the polymeric film to the solidified foamed firstthermoplastic material and forming the polymeric layer on the first foamcomponent, and thereby forming the cushioning element; and removing thecushioning element from the injection mold.